A/C Compressor bypass belt diagram?

  • 2005 FORD TAURUS
  • 3.0L
  • 6 CYL
  • 2WD
  • 97,000 MILES
My A/C compressor went out. So, I was wondering if I could bypass the A/C compressor pulley on my car listed above with a 24 valve DOHC and if I can get the belt diagram to do the job.
Do you
have the same problem?
Monday, September 18th, 2023 AT 2:37 PM

2 Replies

Hello, and thanks for your question!

I cannot find a bypass pulley for this engine on the market or even on Amazon. We have the following three options:

1. Replace the A/C clutch and pulley assembly on the compressor (if this is the only part damaged)

2. Replace the A/C compressor (if it has failed internally, we need to replace the accumulator, orifice tube, and condenser, and flush the evaporator).

3. We can try to find a smaller belt that will fit all of the pulleys except the A/C compressor, so the compressor removal is not needed.

I attached the instructions for the A/C compressor removal below and the serpentine belt diagrams. You will first need to have the system evacuated by a shop with adequate equipment so that the refrigerant does not enter the atmosphere. There is a separate cam driven water pump on these engines with their own dedicated belt on the driver's side of the engine. If you are feeling like replacing that belt, I attached those diagrams also, but there may or may not be a tensioner for that (so I included both). Without the tensioner the belt will have to be cut off and the new one stretched on. Let me know if you need help with this and I will be glad to give you tips on the installation. Please see below:


Removal and Installation

- If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system.
- If A/C flushing equipment is available, carry out the flushing of the air conditioning system prior to installing a new air conditioning compressor.
- If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed.
- Install a new evaporator core orifice as directed by the A/C flushing or filtering procedure.
- Install a new suction accumulator as directed by the A/C flushing or filtering procedure.

- Refrigerant Compressor Oil F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to R-134a refrigerant systems as an A/C compressor lubricant. PAG Refrigerant Compressor Oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant.

- If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.
- Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

1. Position the vehicle on a hoist with the gear selector in NEUTRAL.
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
3. Remove the accessory drive belt from the A/C compressor pulley.
4. Remove the RH radiator cooling fan.
5. Remove the lower radiator air deflector.

6. Remove the bolt and detach the compressor manifold and tube assembly.
- Discard the O-ring seals.

(See image 4)

7. Disconnect the field coil electrical connector.

(See image 5)

8. Remove the two lower A/C compressor bolts.

(See image 6)

9. Disconnect the compressor manifold and tube fitting at the suction accumulator.
- Discard the O-ring seals.

(See image 7)

10. Remove the three bolts and the bracket.

(See image 8)

11. Remove the two upper A/C compressor bolts and the A/C compressor.

(See image 9)

12. To install, reverse the removal procedure.

Let me know how it goes, or if you need any further assistance, we are here to help!

Was this
Monday, September 18th, 2023 AT 7:03 PM

Looking at the belt routing diagram, it doesn't appear it can be done with this engine. See pic below.

If you use a shorter belt and bypass the compressor, it appears the belt will hit the compressor clutch pulley. So, we have three things we can try.

First, what is wrong with the compressor clutch? With the belt removed, are you able to turn the clutch pulley by hand? If you can, disconnect the power to the compressor (one connector) which will prevent it from trying to engage and damaging the belt.

Next, if the compressor pulley is locked and can't be turned by hand, you may want to find an AC compressor bypass pulley. This would take the place of the compressor and you can use a standard belt. I tried looking for one, but was having trouble finding one that will work with this engine.

Last, you could remove the compressor completely making room for a different size belt. Basically, you would route the belt the same as it is but without the compressor in the way, you could go from the crankshaft pulley to the power steering pump pulley.

If that is an option (and I recommend measuring the belt in advance) I believe Dayco belt 5060820 will work. But again, please confirm that.

Let me know if this helps or if you have other questions.

Take care,


See pics below.
Was this
Monday, September 18th, 2023 AT 7:13 PM

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