AC compressor clutch diy

[H16bill]

Just finished this job. AC stopped working. Took it into dealer for diagnosing. Compressor clutch failed. Estimate $2400. Ordered $47 clutch kit from eBay. Has new pulley with bearing. Took about 6 hours but fit perfectly and AC is cold again. Checked continuity on old clutch and it was open, infinite ohms. I did not remove the compressor or Freon. I did read the e53 threads before attempting. If you decide to do this, get the best circlip pliers you can find. They can’t be too long because you only have ~7” between compressor and radiator. I bent the handles on mine to fit. Might save you 3 hours.
Remove top brace, 13mm
Remove fan
Remove belt, t60 Torx
Put cardboard over radiator
Remove outer clutch plate, 10mm bolt, center hole is threaded so you can use larger bolt as puller.
Remove circlip. This one has gaps you can get a small screwdriver in after it is started. Hope your circlip pliers are better than mine.
Remove pulley with small 2 jaw puller. Put bolt back in center so you don’t mess up threads.
Remove coil circlip. It’s about an inch in the circular groove. Need a small mirror to see it. I ended up looking it over and then feeling my way with the circlip pliers.
Remove wiring bracket, 8mm wrench and #1 Phillips. It is partially under tube.
Whew! Reassemble with new parts.