So I tore it all apart again and found that the long bolt that goes through the alternator and engine block is just to thin? I put the bolt just through the engine block and it had quite a bit of play so I'm pretty sure its rattling where the bolt goes through the block. Of course this doesn't make any sense because its the original bolt that came from the factory. I compared the new and old alternators and they are exactly alike. They both have a tiny bit of play where the bolt goes through the mounting holes but much less than where it attaches to the engine.
Is there some special way to do this? I'm sure that I installed it right and I've talked to our mechanic but its still having this problem.
Does anyone know how to fix this? I was thinking about wrapping tape or something around the bolt to make it a little bigger. Is there a specific sequence or something you have to follow when tightening the bolt / belt.
Please help this is driving me crazy!