Noises are tough, but try getting under the car when the engine is cold and it has been sitting for a while and hit (with your fist) the catalytic converter-the substrate in cats break up and cause rattles that are especially noticable when the vehicle is running at low speeds.
we tried that didnt work =[
well I AM trying to help, and the ONE thumb is really nice of you... like I said, noises are REAL tough to diagnose over the INTERNET, maybe you could use your cellphone and post it on youtube...go onto forums for Aleros, there are lots of them, and the people on those forums might know exactly what your issue might be (google "Alero forum')-maybe a better description like it does/does not seem to have anything to do with the engine, or trans, or brakes...like it might be a suspension issue (does it when it hits potholes or bumps)...thanks again for the ONE thumb, though, good luck with your 'rattle'...
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Most likely, you have a timing chain that is extremely loose and hitting the inside of the timing cover. There is probably a broken timing chain guide or tensioner. I would not operate the engine if this is the case. If the chain comes completely off, it will destroy the entire engine. It can also knock holes in the timing cover and make the engine lose all of its oil...also resulting in the complete destruction of the engine.
It is thats your timing chain smacking the timing cover.Chain and tensioner are worn out.
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