did you try a new regulator valve? also did u have much taken off the head?

did you check or clean the mesh filter in the tensioner??
if its cloged the tensioner wont get full oil pressure..

My rattle lasted about a day or so. That's driving nearly 200km though, with half stop start (freeway traffic jam) and 100km/hr cruises.

Haven't had a problem since, and the head had been skimmed twice making the chain a little longer too. Have you driven it for long?

phong =P~

the noise is definately coming from the chain area. i've shimmed it up with one 2mm washer and it's still the same

the 'lump' on the guide for the tensioner is still there. the guides are not broken (or if they are, i can't pull any broken bits out, or see any cracks).

the noise disappears over approx 2000rpm (haven't connected throttle cable yet so haven't seen tacho).

the chain does appear to be tight around the cam gear but to me it seems too easy to move on the right (inlet) side, using a screwdriver. i'm pretty darn confident i've been releasing the tensioner correctly.

not sure how much was taken off the head - i asked for it to be cleaned, faced and pressure tested. i'll call and ask and see if they can remember. this is at least the 2nd time the head has been done, though.

i think the combination of a machined head and AU gasket has just put too much slack in the chain. i'll try shimming another washer or two (going to be careful here...) and maybe a new tensioner. from there i guess i can try a new chain and guides as if this is the original one it's done 257k now and probably a little stretched.

here's a vid of the noise. excuse the half-assembled engine, i didn't go any further with re-assembling once i heard the noise. the rapid tick you can hear is coming from the PCV valve, so ignore that, i've been meaning to replace it.

http://www.youtube.com/watch?v=P83Tppwrr_E

yeah that definitely is the timing chain....try removing the tensioner and putting pressure on the guide with a rod or something...get an assistant to start the car....this is just an idea that ive never tried

got it together and driving now - funny thing is, you can't hear the noise at all while driving, and even with your head under the bonnet, you really need to be listening carefully to pick it up now that the belt is on and all the accessories are spinning too. wouldn't surprise me if the noise has always been there....