Wow, gotta have that tool in my collection. Seeing it at homedepot for $29.

https://www.homedepot.com/p/Stanley-...-962/203740742

You don't use it often, but when you do... it's a god send. Mine is a telescoping version from Lowe's by Kobalt. Goes from ~7" long to about 10 or 11" when more torque is needed (or more clearance).

Edit: Here you go... it's this one.

https://toolguyd.com/kobalt-double-drive-ratchet/

I notice a hanging hole you could put a screwdriver for torque


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Ok we have an update, Day 10 and it’s out!!

I went to our hardware store Bunnings (like Home Depot) to see if they had any tools like the ones that were suggested and they looked at me crazy, I then showed some pics and they were like wow we have never seen that before.

So I then went back home and persisted with the tool I had slowly slowly till I could turn it by hand and finally it dropped out.

You can pull the compressor out with the lower radiator hose still attached, you just have to be careful and protect the radiator fins.

Now I’m not looking forward to putting it back in, I think I’ll just put in the two bolts in the front and see how I go, if it moves I’ll re-assess the third bolt.

Thank you to Andrew and everyone who contributed to this saga, I hope this thread helps some other poor soul who finds themselves in such a situation.

As BMW don’t document this install well, this step by step guide should help others know what to do and what you don’t need to do.

Below is a pic of the tight quarters the AC compressor sits in and all the things in the way.

Aaarrgghh just when I thought smooth seas ahead the nightmare continues, got compressor into place & tried to do the bolts up and the X5 says no the sleeves are now stripped despite being lined up and lube placed on the bolts.

I don’t know who the sadist was who designed & decided on the location of the compressor and having these bolt sleeves, was hoping to have it on the road again today but the sleeves have put a stop to that.

Absolutely everything is calculated to make your life a complete nightmare when fixing the car, it mainly stems around accessibility & special tools & having to remove unnecessary parts to gain some access.

Does anyone know the part number of the sleeves? It’s the two front ones that the compressor bolts too at the front of the engine N62

I’m tipping dealer won’t have in stock either.

Do not attempt this Job at home, it’s better for your sanity to be bent over at the stealership for this Job.

04 4.4 A/C Compressor Removal
 

I think I saw the sleeves on real OEM.

https://uploads.tapatalk-cdn.com/201...12bbc41e2f.jpg

Oops sadly just a mention in the repair manual didn't have the part #.

Pull them out chuck into a drill and spin against a file. Or if they are symmetrical flip them around and put the damaged part into the block. (or likely a bit of both)

Sadly the geometry says that the back bolt.holds all the pressure of the belt you really need to have it in there however: nobody said the head has to be buried!

Get a longer bolt, get a piece of tubing that just fits over the bolt and cut it just right until the bolt head is visible out the side of the compressor and you can get a 12-side box end wrench on it (or do the classic flip flop with an open end wrench).

https://www.pelicanparts.com/More_In...2-1-726-238-M9

I think this is the size.

You can maybe extract the part #.

It's called a locating dowel sleeve.

You can’t get a longer bolt in the rear sadly, you just can’t manoeuvre it in and it’s shorter than the front two for this reason.


Turns out the sleeves are ok, and I tightened up both front bolts, started reassembling everything, and tightened the rear(not super tight) to find a spacer missing that sits between the engine and compressor. It had fallen in many of the hidden crevices.

I’m now wondering if I should pull it all out again or just leave it on without it.

I've never done this type of repair but experience tells me it's better to play safe and pull it now rather than later after the system has been recharged, at which point you will have to redo more than necessary. Just reassemble as designed. Failure to do that could be "what made the rocket launch" fail.

If that spacer goes between the back foot and block it's pretty important It determines the angle of the pulley.