When replacing the belts on my 81' 240, I couldn't get the A/C belt loose enough to get it off. So I just cut it off because the a/c doesn't work anyway. Then, the new belt was too tight to get back on (surprise!), so i just put the alternator belt and PS belt on and called it a day.

What I'm wondering is if not having the A/C belt on there will throw something off in the bottom end in the long run or if it's no more damaging than having a benz without A/C

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'95 Geo Metro 3-cyl 5-speed
'97 Geo Metro 3-cyl 5-speed x2
'81 Mercedes 240D 4-speed manual RIP

Don't worry about it. The only drawback is the Benz with no A/C part. I am still trying to get over that hurdle since it is getting pretty hot here in Nevada

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1981 240D/297K/4-spd/OM617 (mine)
1982 240D/241K/4-spd (wife's)
1979 240D/291K/4-spd/OM617 (father-in-law's)
1983 300DT/240K/4-spd (brother-in-law's)
1985 300DT/???K/5-spd Intercooler conversion (brother-in-law's)
1985 280TE/160K/5-spd (father-in-law's)
1963 UNIMOG (brother-in-law's)

If it mounts the same way as the 617 I feel your pain. I did my belts a couple weeks ago and the AC was a PITA. I had to loosen up all the bolts in back and pry the thing loose to slide enough to get the belt off. Getting it on was the same story, had to put a bit around the crank pulley and turn over the engine to get it to seat right. A week later I hear a noise and I realize the AC belt was loose and flapping all over the place. I ended up re-loosening the mounting bolts, pushing it as hard as I could with my right hand while tightening with my left. What a pain, but it is ok now.

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TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth

Using the tensioner on the compressor mount eliminates much of the pain.

^^I'll do the same with the belt by "starting" it on the pulley and use a hand held bump switch to just turn the engine over.

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83 SD

84 CD

did you loosen the adjustment bolt on the driver side of the engine? it is just forward of the primer pump 10mm I believe.

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1982 300CD Turbo (Otis, "ups & downs") parts for sale
2003 TJ with Hemi (to go anywhere, quickly) sold
2001 Excursion Powerstroke (to go dependably)
1970 Mustang 428SCJ (to go fast)
1962 Corvette LS1 (to go in style)
2001 Schwinn Grape Krate 10spd (if all else fails)

Tensioner was broken or something, I had it loosened all the way when I put it on and then tightened all the way after, and it was still flapping all over the place - almost so bad it was about to fly off. The only way I could get it tight is by the push-tighten method, which takes quite a bit of energy and muscle.

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TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth

I just redid my AC system and the tensioner is an awesome feature for belt tightening. I had to crank it quite a bit, not sure if I could have gotten it tight enough not to slip without it. I replaced my compressor so I was able to get all of the parts clean and burr free, so it worked perfectly. If you have your compressor off I would suggest getting the tensioner working properly, it will make it a lot easier

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1982 300CD Turbo (Otis, "ups & downs") parts for sale
2003 TJ with Hemi (to go anywhere, quickly) sold
2001 Excursion Powerstroke (to go dependably)
1970 Mustang 428SCJ (to go fast)
1962 Corvette LS1 (to go in style)
2001 Schwinn Grape Krate 10spd (if all else fails)

The tensioner operates with a bolt through a plastic threaded piece which in my 82 240 was broken.
You have to remove the comp to access the piece and replace it.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

If I ever have the compressor out, it is definitely on the list. For now, not a biggie as my AC doesn't even work (now wondering why I went through the trouble to put the belt on...). I'm not too worried about it - only something I have to deal with if I have to change a belt.

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TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth

Sorry, but I was thinking about the PS pump adjuster not the comp.
On my 81 I also cut my ac belt off because I did not want to deal with my ac at all and so did not want the extra drag on the motor.
In my 82 I think I used a big screwdrier to lever the comp while I tightened the bolts.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily