I've been chasing an electrical gremlin in my "new" '92 740 wagon. The AC compressor is blowing the #16 (30A - Manual Climate Control/AC) fuse. In order to rule out a loose wire or something, I've checked voltage everywhere I can think of. I've cleaned and greased the grounding terminal on the engine block. The control unit was replaced just before I bought the car, probably in an attempt to fix this same problem. They did at least make a good effort ($487). I resoldered the connections indicated in the FAQ anyway, just to rule it out.

Now, when I run a completely separate wire (to rule out a problem in the wiring harness) from the positive end of the low pressure switch connector to the positive compressor wire, the compressor runs normally for about 15 seconds (cools perfectly), then blows the #16 fuse again. The low pressure switch connector will then be hot to the touch, as will the connector at the compressor.

This makes me suspect that there's an electrical short inside the compressor clutch itself, possibly grounding out early and blowing the fuse. Has this happened to anyone, and if so, can the clutch be removed/repaired/replaced as needed while keeping the current compressor? What tools are needed, and is this a DIY job?

Thanks in advance.

RHaire - Thanks for your suggestion from a few days ago. I had hoped my problem would be the same as yours.
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Guid ('88 244DL 213k, '89 744T 167k, '92 745 163k)