How to replace the AC compressor with a pulley in a pontiac sunfire

Written by mark robinson
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How to replace the AC compressor with a pulley in a pontiac sunfire
A bypass pulley can keep your car on the road. (Jupiterimages/ Images)

Bypass pulleys are a popular option for those who are in the middle of changing their AC compressors. These pulleys are installed in place of the AC compressor to provide a working pulley for the most accessory belts. Bypass pulleys come in handy on vehicles fitted with single serpentine belts, especially in cases where a shorter belt cannot be substituted. It is advised that the air conditioning system is purged of Freon by an experienced service technician before removing the compressor.

Skill level:

Things you need

  • Socket wrench set
  • Floor jack
  • Jack stands
  • AC bypass pulley

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  1. 1

    Ensure that the air conditioning system is not pressurised and free of Freon. If the system still contains Freon, have an experienced service technician remove the Freon from the air conditioning system. Do not release the Freon into the atmosphere.

  2. 2

    Open the bonnet and disconnect the negative terminal cable from the battery. Locate the serpentine belt routing diagram near the front of the Sunfire's engine compartment. If the diagram is not available, refer to your owner's manual for the proper belt routing.

  3. 3

    Place a socket wrench with the proper socket on the bolt in the middle of the belt tensioner pulley. Rotate the tensioner clockwise to slacken the belt and pull the belt from the pulleys.

  4. 4

    Raise the front end of the vehicle with a floor jack and support it with jack stands to gain access underneath the engine bay. Locate the electrical connection to the air conditioning compressor and unplug it. Remove the bolt holding the air conditioning lines to the rear of the compressor.

  5. 5

    Use the socket wrench to remove the bolts holding the air conditioning compressor in place. Carefully guide the compressor through the bottom of the vehicle and out of the engine bay.

  6. 6

    Mount the bypass pulley in the former location of the compressor. Secure the pulley to the mounting surface with the same bolts used to hold the compressor. Tighten the bolts with the socket wrench.

  7. 7

    Use the belt routing diagram to reinstall the serpentine belt. Rotate the tensioner clockwise and slip the belt onto the tensioner pulley. Insure that the belt lines up properly with all of the pulleys.

  8. 8

    Reconnect the negative terminal cable to the battery and close the bonnet.

Tips and warnings

  • EPA regulations prohibit the intentional release of Freon and other refrigerants. Always use the proper reclamation equipment to remove and store Freon.

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