Removal

1. Drain oil by turning compressor upside down and draining oil through suction valve.
2. Remove compressor clutch assembly as follows:
a. Using clutch hub wrench, KV99412306 or equivalent, hold clutch hub and remove shaft nut from shaft.
b. Using hub nut socket KV99412305 or equivalent, remove clutch hub nut, then remove spacers.
c. Using clutch hub puller, KV99412306 equivalent, remove clutch hub. Thread tool into bore of clutch hub, hold tool with wrench, and thread in center bolt.
d. Flatten lock washer tab with suitable screwdriver.
e. Loosen locknut using locknut socket, KV99412310 or equivalent. Remove locknut and lock washer.
f. Remove pulley and bearing assembly. If assembly cannot be removed by hand, use tool Nos. KV99412312 and KV99412313 or equivalents.
g. Loosen six coil mounting screws, using suitable impact tool, then remove mounting screws and separate coil assembly.
3. Using suitable pliers, remove shaft seal retaining ring, then remove shaft seal as follows.
a. Plug suction and discharge openings of compressor.
b. Wrap rag around shaft and apply 28-71 psi from low pressure service valve of compressor and receive seat in rag.
c. If shaft seal cannot be pulled out, reset it to original position and apply refrigerant pressure again.
d. Using shaft seal remover and installer 6KV99412321 or equivalent, insert tool through open end of front cover. Depress carbon seal and hook tool at case projection of shaft seal. Remove seal by slowly pulling out tool.
4. Remove discharge valve.
5. Remove rear cover and components to expose rear cylinder head as follows:

Fig. 6 Rear end cover bolts removal & installation sequence. Hitachi compressors:

a. Using suitable tool, remove five rear end cover attaching bolts. Starting at top, loosen all bolts one turn in an alternating pattern, Fig. 6, then remove bolts in turn.
b. Grasp rear end cover and carefully separate it from compressor. Tap flange lightly and alternately as required with suitable hammer. Do not tap on compressor shaft.
6. Remove cylinder assembly from compressor shell, tapping shell lightly with suitable hammer as necessary. Do not tap compressor shaft. Detach front cover from shell.
7. Remove shaft seal from shaft if not previously removed.
8. Remove two O-rings, cylinder head, suction valve plate, gasket, two pins, and O-ring. When removing two pins, proceed carefully to avoid cylinder head damage. Do not deform suction valve plate when removing it. Discard old gasket and O-rings.