1991 300d basket case volume 2

[bfrinkus1]

Howdy folks, back again. You gave me such fantastic help on my first post, I'm back for more. Quick refresher, I purchased a cheap 1991 300d 2.5turbo with 225k and got exactly what I paid for. Trying to make quality repairs to get her back on the road and keep her there for another 225k.

-I saw the serp belt with shoulder wear, quick visual indicated tensioner arm cocked sideways. I removed arm and will be replacing it. However, I was troubled by wear to the bolt that holds the arm to the block. Picture attached, please advise if this is as bad as it looks.

-Obviously the fan/clutch assembly had to come off, but before removal I saw that it looked very wobbly when rotating. Part of a fan blade damaged and wrong bolt securing fan/clutch to water pump pulley. Pics attached. Please tell me correct allenhead bolt (length, pitch, etc) to replace the incorrect hardware and tell me if you think fan blade damage is bad enough to require replacement. (Note: I could be wrong, but wobbling appeared to be caused by incorrect hardware, not fan imbalance).

-There is metal cover on the vacuum pump that is leaking oil at the bottom. I gently tried prying cover off to see if there was a gasket underneath, but it didn't seem to want to come off. I've read that these cars tend to have problems with the vacuum pump...do I have to replace pump to fix leak, and SHOULD I replace pump just as a precaution?

-My ABS light is on and I was advised to check charging voltage. With no accessories on, it's charging low 13s at idle, mid-high 13s revved up. With all accessories on, it's charging 12.5 at idle and mid 13s revved up. This seems low to me so I removed it for inspection. Brushes on regulator look great, so I took it to my local automotive big-box retailer. They tested and said it was fine. They also said that it was only supposed to be a 70amp unit, is this correct? I plan on taking it to a specialty alternator/generator shop for additional testing on Monday, but wanted y'alls thoughts on this.

-I'm pretty sure my AC compressor is shot (clutch engages and turns when I put R134 in it, but it does not generate any suction or discharge pressure), but I also think system has a small leak (system only had 10psi when I first checked it). I injected UV dye, but haven't found the source of the leak yet. Are there any common places these things leak that I should make sure to check?

You guys (and girls!) are awesome, thank you for your valuable insights.

Many thanks,
Brad