Sounds like your work wagon is creating weekend projects for you.

The alternator mounting ear egg-out is a common result of too-tight belts and ruined rubber bushings and a loosened locknut. I've heard some poly bushings fall apart in no time, but no one comes back and says why-- they just blame the manufacturer -- or worse, the store selling them. No feedback on the oil/heat/belt-adjustment factors.

I'm not sure, but I believe I have seen those housings sleeved. Like maybe the later ones from Bosch are. Anyhow, you need the new bolt, a new all-metal lock nut, and another alt -- or see if you have a local rebuilder who can spiff it up for you. I use the rubber bushings. Just the buck-and-a-half rubber ones, not OE Genuine Volvo, and have OK service as long as there's no oil running over them. That's what kills your water pump donut seal too -- the oil.


--
Art Benstein near Baltimore

Those who get too big for their britches will be exposed in the end.