Dorman 34298 A/C Compressor Bypass Pulley Instruction Manual

1. Introduction

1.1 Product Overview

The Dorman 34298 A/C Compressor Bypass Pulley offers a practical and cost-effective solution for vehicles where the original A/C compressor is inoperable or has been removed. This bypass pulley allows the existing serpentine drive belt to be retained and used, ensuring proper function of other engine accessories without the need for a different length belt.

Key features of this product include:

• Cost-effective solution: Retains the use of the standard drive belt after a failed A/C compressor is removed.
• Durable components: Manufactured with quality materials for a long service life.
• Easy to install: Designed to use the same mounting points as the original A/C compressor.
• Quality tested: This part has undergone extensive testing to ensure a quality fit and long service life.

1.2 What's in the Box

• 1 Bracket
• 1 Pulley

Figure 1: Dorman 34298 A/C Compressor Bypass Pulley

2. Safety Information

Always prioritize safety when working on a vehicle. Failure to follow safety precautions can result in serious injury or damage to the vehicle.

• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is securely supported on jack stands or a lift before working underneath it.
• Disconnect the vehicle's battery before beginning any electrical work.
• Allow the engine to cool completely before working on engine components.
• If working with refrigerants, ensure proper recovery equipment is used by a certified professional to prevent environmental harm and personal injury.
• Refer to your vehicle's service manual for specific torque specifications and additional safety guidelines.

3. Tools Needed

For the installation of the Dorman A/C Compressor Bypass Pulley, you will typically need the following tools:

• Ratchet and appropriate sockets
• EPA approved A/C Refrigerant recovery equipment (if refrigerant is present in the system)

4. Installation Instructions

The following steps outline the general procedure for installing the Dorman A/C Compressor Bypass Pulley. Always consult your vehicle's specific service manual for detailed instructions and torque specifications.

1. Recover Refrigerant: If the vehicle's A/C system contains refrigerant, recover it using EPA approved A/C refrigerant recovery equipment. This step is crucial for environmental protection and safety.
2. Remove Compressor Connections: Disconnect any electrical connectors and lines attached to the A/C compressor.
3. Remove Serpentine Belt: Loosen the tensioner and carefully remove the serpentine belt from the A/C compressor pulley.
4. Disconnect A/C Lines and Bolts: Remove the bolts securing the A/C compressor and disconnect all A/C lines from the compressor. Be prepared for any residual refrigerant or oil.
5. Remove A/C Compressor: Carefully remove the A/C compressor from its mounting location.
6. Insert Bushings: Insert the provided bushings into the mounting holes of the Dorman bypass pulley bracket. Ensure the bracket is centered properly.
7. Install and Tighten Bolts: Position the bypass pulley bracket in the former A/C compressor location. Insert the bolts through the mounting holes with the bushings and securely tighten them to the manufacturer's specified torque.
8. Install Serpentine Belt: Re-install the serpentine belt, ensuring it is correctly routed over all pulleys, including the new bypass pulley. Check for proper fit and tension.

4.1 Additional Steps for Belt Fitment

If the serpentine belt does not sit properly on the bypass pulley after initial installation, follow these additional steps:

1. Remove Serpentine Belt and Pulley: Remove the serpentine belt again. Then, remove the bolt holding the pulley to the bracket and carefully remove the pulley from the bracket.
2. Place Washer: Place the provided washer behind the pulley on the bracket. This washer is designed to provide the necessary space for the belt to ride properly on the pulley.
3. Re-install Pulley: Re-install the pulley onto the bracket, ensuring the washer is correctly positioned. Securely tighten the bolt.
4. Re-install Serpentine Belt: Re-install the serpentine belt and check for proper fit and tension once more.

5. Maintenance

The Dorman 34298 A/C Compressor Bypass Pulley is designed for long-term, maintenance-free operation. However, regular inspection of your vehicle's serpentine belt system is recommended.

• Periodically inspect the serpentine belt for cracks, fraying, or excessive wear. Replace the belt if any damage is observed.
• Check the bypass pulley for any signs of unusual noise, wobble, or resistance when spun by hand (with the engine off and belt removed).
• Ensure all mounting bolts remain securely tightened.

6. Troubleshooting

If you encounter issues after installing the bypass pulley, consider the following:

• Belt Noise: If you hear squealing or chirping from the belt, check the belt tension. The belt may be too loose or too tight. Also, inspect the belt and all pulleys for proper alignment and wear. Refer to Section 4.1 if the belt is not sitting correctly on the bypass pulley.
• Vibration: Excessive vibration could indicate an improperly seated pulley or bracket. Re-check all mounting bolts and ensure the pulley spins freely without wobble.
• Incorrect Belt Routing: Double-check the serpentine belt routing diagram for your specific vehicle to ensure the belt is installed correctly.

For persistent issues, it is recommended to consult a certified automotive professional.

7. Specifications

8. Warranty Information

Dorman Products typically offers a limited lifetime warranty on many of its automotive replacement parts, covering defects in material and workmanship under normal use and service. For specific warranty details pertaining to your Dorman 34298 A/C Compressor Bypass Pulley, please refer to the warranty documentation included with your purchase or visit the official Dorman Products website.

9. Customer Support

For further assistance, technical support, or to inquire about Dorman products, please contact Dorman Customer Service:

• Website: www.dormanproducts.com
• Refer to the packaging for specific contact numbers or email addresses.