well I just bought my beautiful Volvo 2 months ago. Since then my alternator mounting bracket bolt into my block has broken now for the third time. I don't know if this is normal or not. The proper bolts were bought and it was installed properly, yet it keeps snapping. I was wondering if this was a common problem, if so what is this fix. My ideas were having it welded or having a machinist make me a different bracket that doesn't have the bushing on it. Could the bushing be bad? Any answers would be much appreciated. The volvo is a 4 cyl. 240 dl 1983 Sedan.

 

No, it's not normal for the bolt to break. Alignment problem?

 

Sounds like you may be doing something wrong. Those bolts should last 25 years. But first make sure the alternator pulley is lined up with the crank pulley and the belts are straight. If the pulley is cocked at an angle it could be because the mounting bushings are shot.

The adjuster bolt is a long skinny thing about 4" long. It has a 10mm hex head. That's the one that adjusts the position of the alt in order to increase or decrease belt tension. But before you mess with that skinny bolt you have to loosen the lock bolt that holds the adjusting bolt. The lock bolt has a 13mm hex head. If you try to crank the adjusting bolt without first loosening the lock bolt, the adjuster bolt will snap.

It also helps to loosen the pivot bolt, 13mm head, at the bottom of the alt to make it easier for the alt to pivot.

You don't need to have anything welded. Once the pivot bolt and the lock bolt are loose the adjusting bolt should have no resistance to turning except when the belts are tight. Don't get them too tight. 1/2" play in the middle of the belts is about right. Don't pry anything. Once the belts are tensioned properly, tighten the lock bolt in the adjuster assembly. Finally tighten the pivot bolt.

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