Dorman 34272 A/C Compressor Bypass Pulley User Manual

1. Product Overview

The Dorman 34272 A/C Compressor Bypass Pulley offers a practical solution for vehicles with an inoperable A/C compressor. This component allows the original equipment drive belt to continue functioning by bypassing the faulty A/C compressor, eliminating the need for a different length belt. It is engineered with durable components to ensure a long service life and is designed for straightforward installation using the existing A/C compressor mounting points.

Key Features:

• Cost-effective solution: Retains the use of the standard drive belt after A/C compressor removal.
• Durable components: Constructed with quality materials for extended service life.
• Easy to install: Utilizes the same mounting points as the original A/C compressor.
• Quality tested: Undergoes extensive testing for proper fit and durability.

2. What's in the Box

• Bypass Pulley Bracket
• Pulleys

3. Installation Instructions

This section provides a general guide for installing the Dorman A/C Compressor Bypass Pulley. While the video below demonstrates a similar Dorman bypass pulley (model 34190), the installation principles are largely applicable to model 34272. Always refer to your vehicle's specific service manual for detailed instructions and safety precautions.

Tools Needed:

• Ratchet
• EPA approved A/C Refrigerant recovery equipment (if applicable)
• Appropriate sockets and wrenches

Installation Steps:

1. Recover Refrigerant: If your vehicle's A/C system is still charged, recover any refrigerant remaining in the air conditioning system using EPA-approved recovery equipment. This step is crucial for environmental safety and personal protection.
2. Remove Electrical Connectors: Disconnect any electrical connectors attached to the A/C compressor. Ensure the vehicle's battery is disconnected before performing electrical work.
3. Remove Serpentine Belt: Loosen the tensioner and carefully remove the serpentine belt from around the A/C compressor and other pulleys.
4. Disconnect A/C Lines: Remove the bolts securing the A/C lines to the compressor and carefully disconnect the lines. Be prepared for any residual refrigerant or oil.
5. Remove A/C Compressor: Unbolt and remove the A/C compressor from its mounting bracket.
6. Prepare Bypass Pulley: Insert the provided bushings into the mounting holes of the new bypass pulley bracket. Proper centering of the bracket is important for correct belt alignment.
7. Install Bypass Pulley Bracket: Position the bypass pulley bracket in place of the removed A/C compressor. Insert bolts through the mounting holes with bushings to center the bracket, then securely tighten all bolts to the manufacturer's specifications.
8. Install Serpentine Belt: Route the serpentine belt around all pulleys, including the new bypass pulley. Ensure the belt sits properly on all grooves. Check for proper fit and tension.
9. Adjust for Proper Belt Fit (if necessary): If the serpentine belt does not sit properly on the pulley, it may be necessary to adjust the pulley's position. Remove the serpentine belt, then remove the bolt holding the pulley to the bracket and remove the pulley. Place a washer behind the pulley on the bracket. This washer will provide the necessary space for the belt to ride properly on the pulley. Re-install the pulley and secure it with the bolt.
10. Final Belt Installation: Re-install the serpentine belt, ensuring it is correctly routed and tensioned. Double-check that the belt is seated correctly on all pulleys, especially the bypass pulley.

4. Operating the Bypass Pulley

The Dorman 34272 A/C Compressor Bypass Pulley is a passive component designed to maintain the serpentine belt's routing and tension after the A/C compressor has been removed. Once installed correctly, it requires no active operation. The vehicle's engine will operate as normal, with the serpentine belt driving all other accessories, excluding the A/C compressor.

5. Maintenance

The Dorman 34272 A/C Compressor Bypass Pulley is designed for long-term, maintenance-free operation. However, periodic inspection is recommended as part of routine vehicle maintenance:

• Visual Inspection: Regularly check the pulley for any signs of wear, cracks, or damage. Ensure the bracket is securely mounted and all bolts are tight.
• Belt Condition: Inspect the serpentine belt for fraying, cracks, or excessive wear. Replace the belt if necessary, ensuring it is correctly routed over the bypass pulley.
• Noise Check: Listen for any unusual noises coming from the pulley area, such as squealing or grinding, which could indicate a bearing issue or improper belt alignment.

6. Troubleshooting

If you experience issues after installing the bypass pulley, consider the following troubleshooting steps:

• Belt Squealing: This often indicates improper belt tension or misalignment. Re-check the serpentine belt routing and tension. Ensure the bypass pulley is securely mounted and aligned with other pulleys. The additional washer step in the installation guide may be necessary.
• Unusual Noises (Grinding/Rattling): This could suggest a faulty pulley bearing or loose mounting bolts. Inspect the pulley for free rotation and check all mounting bolts for tightness.
• Belt Slippage: Verify that the belt is correctly seated in all pulley grooves. Ensure the belt is the correct length for your application and is properly tensioned.

If problems persist, it is recommended to consult a certified automotive professional.

7. Specifications

8. Warranty and Support

Dorman is committed to providing quality automotive replacement products. For specific warranty information regarding your Dorman 34272 A/C Compressor Bypass Pulley, please refer to the documentation included with your purchase or visit the official Dorman Products website. Dorman has been a trusted name in the automotive aftermarket for over 100 years, offering solutions engineered to save time and money, and increase convenience and reliability.

For further assistance or technical support, you may contact Dorman customer service directly through their official website or authorized distributors. Always ensure you have your product model number (34272) and purchase details available when seeking support.