Fitted new pulley now Aux. belt to small?

[cogs]

With reference to the V40 B42045S2 1948cc engine.

I seem to have encounted a strange problem with my drive belt. As you may have seen in my other post https://www.volvoforums.org.uk/showthread.php?t=336899
the alternator pulley decided to self destruct. I decided to replace the timing belt etc. and clean the vvt pulley while doing the repair.

Today I thought I'd finally get the job finished, I've been waiting for some dry weather as the last storm removed the roof of my temp. clarke tent garage, I know I wanted better lighting in there but that was an extreme solution.

When it came time to fit the aux. drive belt I couldn't make it fit. I have a new belt which is the same size as the old one but no matter how much I wrangle with it the belt is just to small. I even tried refitting the old belt but again to small. The tensioner is fully pulled back and I've double checked the belt route with Vadis. The belt is 181cm in length and not even close to fitting.

It seems bit of a strange problem and not one I thought I'd encounter. The only thing I can think of is that the original alternator pulley must have been a smaller diameter than the new one. Unfortunately I can't compare the original pulley size as it vanished up the road in a shower of sparks.

I'm going to the motorfactors tomorrow to see what size belts their systems say as online sources like europarts, halfords give various size belts none of which match the original belt length.

Anyone come across this problem before?

[cogs]

I had toget a new belt from the motor factors that was 20mm longer than the original and then it was still a tight fit. Finally on but found another problem.