BMW E60 AC Compressor Replacement – 2006-2010 N52 6 Cylinder

As discussed above, the water pump and thermostat must be removed from 2006-2010 E60 and E61 5 series sedans and wagons in order to remove the AC compressor from the vehicle - there is simply not enough room to get it out any other way. If you were planning on replacing your thermostat or water pump now is the time to do it while they are removed from the vehicle.

1. Raise and support your vehicle so there is plenty of clearance to work safely under the vehicle.
2. Please refer to our article BMW E60 Water Pump Replacement – 2006-2010 5 Series – N52 6 Cyl for complete instructions on removing the water pump and thermostat from your N52 6 cylinder engine.

Removing the AC compressor first requires removing the refrigerant from the system. It is perfectly legal for the home mechanic to remove their own refrigerant as long as you follow the correct procedure and DO NOT knowingly release any into the atmosphere. For more information on removing and recycling the 134a refrigerant from your BMW please refer to the wealth of online articles and videos from other automobile enthusiasts.

1. Begin by removing the 134a refrigerant from the AC system. Per Section 608 of the Clean Air Act, it is illegal to knowingly release automotive 134a refrigerant into the atmosphere and is punishable by fines up to $27,500 per occurrence. Removal of 134a refrigerant from your vehicle's HVAC system must be recycled or reclaimed using the proper equipment. Always use proper safety equipment including eye protection when working on your vehicle's AC system.
2. The refrigerant compressor in E60 and E61 sedans and touring wagons is located at the front right side of the engine block. It is located underneath a maze of coolant lines that will need to be cleared out of the way before the compressor can be removed.
3. Remove the engine cover.
4. Release the metal clip on the expansion tank coolant hose and fold it back out of the work area.
5. Unplug the cylinder head temperature sensor. Remove the two 10mm bolts securing the cylinder head coolant hose and gently fold it back out of the work area.
6. Remove the oil cooler coolant hose from the oil cooler. Move under the vehicle and disconnect the oil cooler hose from the bottom right side of the radiator. BE CAREFUL! It's full of coolant...have a drain pan ready. Tuck the oil cooler hose out of the work area along with the other coolant lines.
7. Locate the low-pressure refrigerant line on the top of the compressor. Remove it with a T40 torx bit.
8. Locate and remove the high-pressure refrigerant line from the compressor using a T40 torx bit.
9. Using a T50 torx bit, turn the main accessory belt tensioner pulley clockwise to release the pressure on the main accessory belt. Remove the belt from the AC compressor and tuck it away out of the work area. It is not necessary to completely remove the belt unless you are replacing it.
10. Using an E12 external torx bit, remove the top compressor mounting bolt.
11. Next, the lower rear mounting bolt must be removed. In order to access the lower rear mounting bolt, the right front wheel must be removed, the plastic lateral trim removed, and the steering wheel turned all the way to the right. This will allow enough clearance to get a socket extension under the fender to access the rear compressor bolt.
12. Using a long socket extension and an E12 external torx socket, remove the rear mounting bolt from the compressor.
13. Finally, while holding the compressor, remove the front mounting bolt. Remove the compressor from the vehicle.

Installing the new compressor is essentially the reverse of the above steps with a few important notes. First, always use new aluminum mounting bolts - never reuse the old ones! Aluminum bolts stretch and should always be replaced. Please see our parts list above to order a set if needed. Second, new compressors come pre-filled with oil - to avoid losing oil, do not remove the plastic plugs on the high and low refrigerant line ports until the compressor is installed. Finally, to avoid the compressor falling out of the bottom of the vehicle and becoming damaged, always install the lower front bolt first. This is the easiest to install and will keep the compressor in place as you install the other two bolts.

1. The new compressor should come prefilled with oil and with plastic plugs installed in the refrigerant line ports. DO NOT remove these plugs until the compressor is installed back on the engine block.
2. Install a new aluminum lower front mounting bolt and hand tighten. DO NOT torque yet.
3. Install a new upper mounting bolt and hand tighten
4. Install a new lower rear mounting bolt. We suggest holding it in place with some tape to avoid having it fall off of the socket when installing.
5. Starting with the lower rear bolt, torque the bolt to 7 Nm (5 ft-lb). Then using a socket wrench, turn the bolt another 180 degress. The bolt is now torqued to factory specifications.
6. Repeat step 5 above on the lower front and upper mounting bolts.
7. Plug the electrical connector back into the compressor.
8. Reinstall the high and low-pressure refrigerant lines. Torque their mounting bolts to 25 Nm (18.5 ft-lb).
9. Reinstall the main accessory belt to confirm it lines up correctly on the compressor's pulley.
10. Do not reassemble any more of the vehicle until the system is thoroughly cleaned and checked for leaks. Please refer to the wealth of online articles on how to do this simple proccedure.

Final reassembly is simply Section 2 steps 1-6 and Section 1 in reverse. Pay extra attention when reinstalling the coolant lines to confirm they "click" properly into place. Also note that the coolant system must be properly bled after it is refilled with fluid. This is an extremely simple procedure that is done automatically by the vehicle's engine control module. For more information on bleeding the coolant system, please refer to our article BMW E60 Water Pump Replacement – 2006-2010 5 Series – N52 6 Cyl. As previously discussed, there are numerous online articles dealing with recharging the AC system with 134a refrigerant. It is a straightforward process that can be performed by any home mechanic. Remember, you do not have to be a licensed HVAC technician to recharge your vehicle's AC system as long as you are not being compensated for the job.