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 clutch hub puller, KV994C5780 equivalent, remove clutch hub. Thread tool into bore of clutch hub, hold tool with wrench, and thread in center bolt.
c. Pry off inner snap ring.
d. Remove pulley and bearing assembly. If assembly cannot be removed by hand, use tool Nos. KV994C5781 and KV994C5782 or equivalents.
e. Remove clamping screws that secure coil assembly leads, remove inner snap ring from coil assembly, then remove coil assembly from front cover.

3. Using suitable pliers, remove shaft seal retaining ring, then remove shaft seal as follows:
a. Using tool Nos. KV994C4531, KV994C4532, and KV994C4559 or equivalents, plug high and low pressure openings of compressor.
b. Insert tool No. KV994C1552 or equivalent into hole in middle of blind cover at low pressure side and connect tool to refrigerant can.
c. Wrap rag around shaft and apply 28-71 psi from low pressure service valve of compressor and receive seat in rag.
d. If shaft seal cannot be pulled out, reset it to original position and apply refrigerant pressure again.
e. Using shaft seal remover and installer KV994C1143 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 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.
c. Remove and discard three O-rings.

5. Support compressor shell with front facing downward. Using suitable mallet, tap at rear end of shell flange, driving shell straight downward. Discard front cover gasket. Detach front end cover from cylinder assembly.
6. Remove shaft seal from shaft if not previously removed.
7. 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.