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I didn't use the 'normal' 115 amp Saab alternator, hence it didn't quite bolt in as you're describing. I used an alternator from a late model 9-3/9-5 with a 130 amp output.
The pulley sat too far forward, so using a shim behind the pulley would have made things worse, so I needed to shave the two rear most bosses and install a couple of shims on the front bosses to push the entire alternator back.
I used the stock 80A alternators pulley, directly mounted onto the new saab alternator, with no shims at all. I even has to shave some material off the alternator from behind the pulley, so it wouldn't foul on the alternators casing.
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