2004 V40 1.9TD air-con compressor bypass

jongriff · May 19th, 2015, 20:47

hi,

im new here and hoping you can help! I just bought a 2004 V40 1.9 turbo diesel and the air-con compressor is seized and the pulley makes a hell of a racket. I cant afford to replace it so I am hoping to bypass the compressor for now by fitting a smaller aux-drive belt. I have read on here that it is possible to do but have found no info as to what size of belt is required.

I found on here a document stating the procedure to replace the belt which is helpful, but i am wondering what is the best way to route the new shorter belt to avoid the compressor? I have attached a drawing, the black is the new route and the grey is the original path of the belt. is this the best way? and if so does anyone know what sort of size belt is required? my original plan was to use the belt off a non-ac car but it looks like the power steering pump is in a different place so would be the wrong size. Any information as to what belt would be very helpful!

Thanks in advance!

jg

Clan · May 19th, 2015, 21:30

Quote:

Originally Posted by jongriff

hi,

im new here and hoping you can help! I just bought a 2004 V40 1.9 turbo diesel and the air-con compressor is seized and the pulley makes a hell of a racket. I cant afford to replace it so I am hoping to bypass the compressor for now by fitting a smaller aux-drive belt. I have read on here that it is possible to do but have found no info as to what size of belt is required.

I found on here a document stating the procedure to replace the belt which is helpful, but i am wondering what is the best way to route the new shorter belt to avoid the compressor? I have attached a drawing, the black is the new route and the grey is the original path of the belt. is this the best way? and if so does anyone know what sort of size belt is required? my original plan was to use the belt off a non-ac car but it looks like the power steering pump is in a different place so would be the wrong size. Any information as to what belt would be very helpful!

Thanks in advance!

jg

Using your method the belt would slide past the alternator pulley, rapidly wear and break wrecking your engine ... , note the original wrap around ...
surely you can find a used pump for £50 and swap it without getting it refilled , i'm sure an AC centre would be pleased to take your gas out for free and re use it .

Biotoxic · May 19th, 2015, 22:55

Hi. If it is a 115 or 105 hp engine then the belt comes/goes from Crankshaft pulley--->under belt tensioner--->power steering---->Alternator--->fixed pulley, belt goes over that pulley if you look at it straight on and then back to Crankshaft pulley.
The belt that you have at the moment is called auxiliary equipment belt. If you are looking for a by-pass then it is normal belt, make sure you state that you dont need the aux one.

More info here: Blast from the past

Regarding suitable belt of the shelf, you need to try few belts before you will find the right one. Or just ask the mechanic to find a suitable belt for it, if he will be a decent guy he will get a job done.

P.S. The cat forgot to add some information at the end of the "blast from the past" thread, booooo.....

P.S.2 Hi Clan, long time no see, how's the car doing?

v40alex · May 19th, 2015, 23:29

Someone posted about this very recently, 6PK1310 worked for them.
http://www.volvoforums.org.uk/showthread.php?p=1915972

jongriff · May 20th, 2015, 11:11

thanks for your help.

Biotoxic: mine is a D4192T3 engine i think, so the 115hp one. The route that you mention is the same as the image I have drawn, and this works on your car? Clan says that it would just rub the alternator and break but i cant see that it could be routed any other way.

alex: thanks for the link, very helpful, i notice that his car was a 2001, not sure if thats the same engine?

clarkey1984 · May 20th, 2015, 17:33

I might be wrong, but as it is, surely the alternator would be spinning the wrong way?

EDIT: I am wrong, oops.

Biotoxic · May 20th, 2015, 23:32

Quote:

Originally Posted by jongriff

thanks for your help.

Biotoxic: mine is a D4192T3 engine i think, so the 115hp one. The route that you mention is the same as the image I have drawn, and this works on your car? Clan says that it would just rub the alternator and break but i cant see that it could be routed any other way.

Yes, I had the same engine... and yes, everything worked fine but it does look strange

jongriff · May 23rd, 2015, 17:43

just an update for anyone searching for this issue in the future!, i fitted a new belt and the car is running great. i used a 6PK1275 and followed the route that i drew above. All working great, the alternator is spinning fine too. Thanks for all the help!

jg

cbarrow · Jul 10th, 2017, 17:56

My much used and stalwart V40 1.9 Diesel (04 plate - 215k miles) has got a knackered air con compressor which has also stripped the belt (I wondered what the smell was). I'd like to keep the car running for another year, but do so as economically as possible. I've been looking up threads about bypassing the air con compressor. Grateful for any advice on how people have got on with bypassing it? Have there been any long term problems, or has it thrown or destroyed the bypass belt? I was thinking of using a 6PK1275 as the previous poster suggested. Many thanks in advance

bobthecabbage · Jul 10th, 2017, 18:38

Will the pulley not freewheel?

If it does you could just remove the fuse or disconnect the wire to the AC compressor.

The wire would be my choice just in case someone decides to replace any blown fuses and lunches your engine!

Disconnect it and tape it up and possibly cut the plug off the compressor side so it can't be reconnected.

May 19th, 2015, 20:47	#1
jongriff New Member Last Online: Jul 28th, 2015 15:43 Join Date: May 2015 Location: aberdeen	2004 V40 1.9TD air-con compressor bypass hi, im new here and hoping you can help! I just bought a 2004 V40 1.9 turbo diesel and the air-con compressor is seized and the pulley makes a hell of a racket. I cant afford to replace it so I am hoping to bypass the compressor for now by fitting a smaller aux-drive belt. I have read on here that it is possible to do but have found no info as to what size of belt is required. I found on here a document stating the procedure to replace the belt which is helpful, but i am wondering what is the best way to route the new shorter belt to avoid the compressor? I have attached a drawing, the black is the new route and the grey is the original path of the belt. is this the best way? and if so does anyone know what sort of size belt is required? my original plan was to use the belt off a non-ac car but it looks like the power steering pump is in a different place so would be the wrong size. Any information as to what belt would be very helpful! Thanks in advance! jg

May 19th, 2015, 22:55	#3
Biotoxic Master Member Last Online: Dec 30th, 2018 08:33 Join Date: Oct 2010 Location: Craigavon area	Hi. If it is a 115 or 105 hp engine then the belt comes/goes from Crankshaft pulley--->under belt tensioner--->power steering---->Alternator--->fixed pulley, belt goes over that pulley if you look at it straight on and then back to Crankshaft pulley. The belt that you have at the moment is called auxiliary equipment belt. If you are looking for a by-pass then it is normal belt, make sure you state that you dont need the aux one. More info here: Blast from the past Regarding suitable belt of the shelf, you need to try few belts before you will find the right one. Or just ask the mechanic to find a suitable belt for it, if he will be a decent guy he will get a job done. P.S. The cat forgot to add some information at the end of the "blast from the past" thread, booooo..... P.S.2 Hi Clan, long time no see, how's the car doing? __________________ Useful threads and information Guide: How to change/adjust timing belt Guide: Fitting LED's This is how S40 1.9 TD engine components looks like Information regarding EGR, problems and solutions A.K.A. Hesitation, sluggishness etc. Last edited by Biotoxic; May 19th, 2015 at 23:06.

May 19th, 2015, 23:29	#4
v40alex I do like a V40 Last Online: Dec 1st, 2018 19:03 Join Date: Oct 2013 Location: North Surrey	Someone posted about this very recently, 6PK1310 worked for them. http://www.volvoforums.org.uk/showthread.php?p=1915972 __________________ Current: '02 V40 1.9TD, '02 V40 T4 Previous: '00 V40 1.9TD, '99 V40 1.9TD, '97 V40 2.0CDi, '87 240DL

May 20th, 2015, 17:33	#6
clarkey1984 Premier Member Last Online: Apr 13th, 2022 09:41 Join Date: Jul 2014 Location: Beccles	I might be wrong, but as it is, surely the alternator would be spinning the wrong way? EDIT: I am wrong, oops. __________________ 02 V40 T4 S, "Sargent silver" she's back!

Jul 10th, 2017, 17:56	#9
cbarrow Member Last Online: Yesterday 20:14 Join Date: Mar 2008 Location: Stamford	another air con bypass needed My much used and stalwart V40 1.9 Diesel (04 plate - 215k miles) has got a knackered air con compressor which has also stripped the belt (I wondered what the smell was). I'd like to keep the car running for another year, but do so as economically as possible. I've been looking up threads about bypassing the air con compressor. Grateful for any advice on how people have got on with bypassing it? Have there been any long term problems, or has it thrown or destroyed the bypass belt? I was thinking of using a 6PK1275 as the previous poster suggested. Many thanks in advance

May 20th, 2015, 11:11	#5
jongriff New Member Last Online: Jul 28th, 2015 15:43 Join Date: May 2015 Location: aberdeen	thanks for your help. Biotoxic: mine is a D4192T3 engine i think, so the 115hp one. The route that you mention is the same as the image I have drawn, and this works on your car? Clan says that it would just rub the alternator and break but i cant see that it could be routed any other way. alex: thanks for the link, very helpful, i notice that his car was a 2001, not sure if thats the same engine?

May 23rd, 2015, 17:43	#8
jongriff New Member Last Online: Jul 28th, 2015 15:43 Join Date: May 2015 Location: aberdeen	just an update for anyone searching for this issue in the future!, i fitted a new belt and the car is running great. i used a 6PK1275 and followed the route that i drew above. All working great, the alternator is spinning fine too. Thanks for all the help! jg

Jul 10th, 2017, 18:38	#10
bobthecabbage Premier Member Last Online: Aug 12th, 2020 21:26 Join Date: Mar 2014 Location: Plymouth	Will the pulley not freewheel? If it does you could just remove the fuse or disconnect the wire to the AC compressor. The wire would be my choice just in case someone decides to replace any blown fuses and lunches your engine! Disconnect it and tape it up and possibly cut the plug off the compressor side so it can't be reconnected. __________________ '04 V40 1.9D

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