Radiator fan bolts just spinning 05 s60 2.5T, about to lose my shizzle

[MikeyS60]

Hey all, I am trying to replace the alternator on my 05 s60 2.5T. I am about to lose my shizzle. I can not get the one bottom bolt out or the alternator at all for that matter without removing the radiator fan. My fan is held in by two 10mm bolts that are going into plastic and look to have some sort of a square locker or something when i look through the hole on the side of them. I can not get these out. They just spin and spin and looks like some little plastic pieces on the side are broken. Anyone have any ideas what i could do to remove these without wrecking it. I am now stuck at a stand still and need this out asap. Thanks so much in advance!!

[oragex]

Perhaps they screw into the square metal piece and got stuck in rust and the piece is spinning along. Can you insert a screw driver to lock the metal piece from rotating ? Are you replacing the entire alternator ? If the pulley clutch works well (see yt to check), you may want to replace only the regulator and you don't have to bring the alternator out from there, just pull the screws all the way without completely removing them and flip the alternator to one side. You also need to unscrew a few times the very bottom bolts under the air compressor, to release the alternator from the lower bracket which is common with the compressor- these bottom compressor bolts are usually stuck in rust so careful not to force. You have videos on Youtube

[MikeyS60]

I was unable to stop what i am assuming is a nut inside the plastic with anything i could jam in there.. Only video that came up for me was an 04 which i thought was the same but had some differences i will go double check those bottom bolts. The two that go through bottom bracket of this alternator that i found are holes that the bolts need to come out of and not u shaped like my truck that you just loosen and slide it off but i will dig a little deeper. thank you for your reply. After vida saying low voltage and tester on battery showed only 11.5 i assumed i needed to replace the whole alternator. gonna be peed if spending this much time trying to get it out i can just find two more bolts and replace a regulator lol

[MikeyS60]

well thank you for that. pully clutch seems to work fine. locks when it should and spins in opposite direction. not quite as smooth as the new one on my bench but maybe it is ok. I will look more into regulator replacing. the left bottom bolt came out the right did not but maybe as you say, when i get the bottom ac bolts loosened it may come. have them soaking in some PB blaster for a bit and hopefully i can get them to turn

[jonesg]

I was unable to stop what i am assuming is a nut inside the plastic with anything i could jam in there.. Only video that came up for me was an 04 which i thought was the same but had some differences i will go double check those bottom bolts. The two that go through bottom bracket of this alternator that i found are holes that the bolts need to come out of and not u shaped like my truck that you just loosen and slide it off but i will dig a little deeper. thank you for your reply. After vida saying low voltage and tester on battery showed only 11.5 i assumed i needed to replace the whole alternator. gonna be peed if spending this much time trying to get it out i can just find two more bolts and replace a regulator lol

on my 04 v70 I found the small signal wire to the regulator had corrosion from sitting 6 months, wouldn't chg,
and no red chg warning light on the dash either.
swapped in a new plug and it puts out 14v now.
I bought a regulator but access is very tight so I left it alone until warmer days.

[oragex]

For the regulator, careful when ordering as the model changed in 2005. Bosch makes them
We have this store in Montreal but you should have similar closer https://www.autolectra.com/volvo-auto-parts

[darrylrobert]

The alternator diodes intermittently failed on mine, when i tested it it worked but would fail when it got hot. got me stuck on the highway soon after the "low battery" warning. The low battery warning is way too low it should be 12v or higher. Of course try the regulator first but you may be wasting your money, just get a replacement alt (i used a used one) and get it fixed.

As for the fan there is a metal clip that it screws into, try using something like a flathead screwdriver to pull the bolt out while turning it.

[SuperHerman]

To remove the two bolts you can cut the heads off as close as possible to the frame. You may have enough wiggle room. If you don't you will have to do some precision grinding until you do.

Once you get the radiator removed you should be able to rebuild the area with some epoxy putty - then embed a nut in the putty, making sure you don't get any on the threads. A trick I do is use the bolt and turn the threads until they create a sufficient hole/dent in the putty. You have to work quick as the putty sets quick. Pay attention to alignment of the embedded nut. You may have to cut down the bolt length to get it to the length you need.

It is common, as cars age, the nut rusts to the bolt and when removing it the plastic breaks as it is weaker than the metal bolts. In MN, it is a constant battle especially with license plates. I usually add some anti-seize.

[MikeyS60]

Yes Herman the things we learn as we go. I am in Ontario. damn road salt.

Thanks everyone for all of your help and suggestions. Once i was able to get those bottom AC bolts loose like Rage said, the alternator basically fell over so i fought and spun and twisted and turned and it finally came out with the fan shroud still in place. fought the new one back in and then spent an hour trying to get that belt back on and dropping my ratchet down in the bottom many many times. but she is done. going to take vida out and double check and then start working on the BCM problem. CEM-1A5F Communication with BCM control module Signal missing

[jonesg]

You might try cutting the bolt heads with a dremel cutoff disk, at least tie wrap the rad to keep it stationary or the tranny hard lines will crack.