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Old 05-23-2017, 01:36 PM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Montana, USA
Vehicle: '86 745, '83 764
Posts: 1,618
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The holes are broken or stripped? It sounds like the engine you got may have been from a car that was in an accident. The alternator mount also holds the fan bearing and in a front end hit could be in the line of impact. Hard for me to imagine someone breaking the bosses on the block just by working on it if that is the issue.

Regardless you will need to come up with a good repair for this, because the alternator bracket is what the crank counterhold tool rests against for tightening the center bolt on the crankshaft. Otherwise you'll need to find another way to hold the crank while you tighten the bolt to 350lbs plus. Failure to achieve the full required torque is guaranteed catastrophic destruction of the engine. There are various ways to do it but make sure you get it all the way tight.

I recommend getting a copy of the Volvo green book for the engine if you will be doing work on it. Correct, both cam pulleys have no key, similar to the 4cyl VW diesels and early TDIs. You need a sprocket counterhold tool to make sure the pulleys don't move as you torque them to the required spec. Volvo's 9995199 tool works well and is easy and cheap to find since it's still in common use on their gas engines too. In general you'll find this engine is a piece of cake to work on IF you have the required tools and complete information. Without them, sometimes the results are not good. Greenbooks are available from various sources online and the tools can be borrowed for free.

What pan and pickup do you have now? The 7 series is almost vertical, 2 series might be 20 or 25 degrees but definitely not 40. None of the stock Volvo pans or pickups will do the job without changes if that is what you need.

The installation in a Pinzgauer or Euro LT van is laid over further though. Maybe you'll want to start with a pan and pickup from one of them. Those pans have deep sumps but are steel instead of the aluminum used for the Volvos, so could be easier to modify.
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86 745 D24T/ZF 345k lifted 2.5"
83 764 D24T/M46 155k
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