Another Theory for Blown #48 Fuses
 

Some of you know I've been having issues with fuse 48 blowing within the first 30 to 60 seconds on mostly cold start ups lately. So, today I was determined to remove & inspect the A/C compressor clutch with the system charged and compressor in place. I pulled the front disc plate off rather easily using screwdrivers inserted carefully in the gap between the disc and pulley. The disc had a thick and thin washer between the compressor shaft and splined mounting hole which I thought was odd.

I could only get the pulley/bearing assembly to move about 1/8". So, after about an hour or so I tapped it back in place and put the c-clip back in. The disc and pulley contact surfaces appeared to have some wear as the raised contact surfaces didn't appear raise up much over the non-contact surfaces in my opinion.

Looking at the 2 washers that were originally inside the disc's splined hole, I assembled it with the thicker of the 2 washers. The disc and pulley gap was so small I couldn't get my knife blade in much less a screwdriver but they were not touching. I compared gaps to the wife's 01 325CI which has a similar looking clutch, and its gap was just a little more open than my new gap on the X5 but tighter than the old gap. I doubt a screwdriver would go in it too.

I didn't get the calipers out until I was totally done but I measured the small washer I left out at .013 and I estimate the washer I assembled in place was about .025 or so.

I continued assembly and once I started the engine I immediately noticed how much quieter the A/C sounded when the clutch engaged and ran! No rattling sound! Plus It did not immediately blow fuse #48! Once good and hot after a test drive there was still no contact between the plate and pulley when de-energized. So, my theory here is when the engine was started cold w/the AC on, my clutch was struggling to fully engage due to too large of a gap and occasionally drawing more than the 7.5 amps of fuse #48. Sorry for the long post. I'm cautiously optimistic......