I'm back again. So far I've rewired the harness from the firewall to the alternator. Added extra grounds, a new battery, battery cable and put in a newer set of brushes into the alternator. Everything seems like it's working. BUT This morning when I started up the car this happened. First all idiot lamps came on when I put in the key like it's supposed to. I turned the key, the car started, the lamps went off like they are supposed to and then in a few seconds they all came on again. They flashed on and off three times about one second each time and then stayed off for the rest of the time. Is this some kind of code? This may have been dumb, but I had 3 sets of brushes, all used, but in very good shape compared to the ones I pulled out. So being cheap I used the best set. They came out of another working alternator from another Volvo. I did not want to hassel with removing the whole alternator for a second time so I just replaced the brushes. They looked identical. Were the brushes just reseating themselves? Are different Bosch alternator brushes incompatable? I will have to wait and see if the battery goes dead this time. This thing is haunted? Any ghostbusters out there?
Ben