OK so I rebuilt the Hitachi unit on the weekend. pretty easy to do, and a well made piece of kit. Here are some photos of the rebuild. Several key points;
I used my Rovacom VCIQ to empty the receiver before disconnecting the air lines, and dropped the car to access height before jacking up the passenger side to get to the compressor, had no issues regarding removing pressurised air lines.
1. Removal and install - the top M10 bolt near the upper edge of the chassis rail is pretty tricky to get to, I used a ratchet 10mm spanner to undo, and a 10mm socket on a wobble bar and uni joint for the reinstall, I was able to get the wobble bar up and behind the compressor and reach the bolt so a win there.
2. The cast alloy of the compressor is pretty soft, take care when tightening screws and bolts, I used loctite and high temp gasket maker.
3. In mine the steel and felt filter had jammed in the dryer on an angle with the desiccant behind it, took a bit of persuasion to get it out, DO NOT use a pick or screwdriver on the inside surface of the dryer to pry it out, as this will allow air to bypass the filter.
4. I opened and checked all the clean air passages, I had no issue undoing the valve outlets after a liberal spray with WD40 and letting it soak, I sprayed the entire compressor then replaced the desiccant while the WD40 soaked in. Caked on dirt just wiped off. There was some black dust and tracking in the galleries, a wipe with a clean rag got it all out, followed by a shot of air.
5. I used compressed air to dry and clean everything out before reassembly.
6. Take your time and do one area at a time, note which parts go where.
photos in order as posted: drier after 192000km/8y8m ; compressor as pulled from the car ; piston with new oring, piston glide seal and ring fitted ; drier with alloy cover ; old desiccant vs new desiccant ; new drier filter installed ; clean air side cleaned out ; big end housing with piston and conrod removed.
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