Best advice I would be able to provide you with at this time might be to remove the lower oil pan and perform a thorough visual inspection. IMO, it would be time well spent! If you choose to remove the oil pan, look closely in the area of the crank gear/timing cover. Sometimes broken material from chain rails can become loosely trapped in this area without causing any major problem. If you do find debris then it’s conclusive, you will need to dismantle the front of the engine.
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I’ve changed the chain tensioner, upper rails, but the problem noise still persists. My chain stretch was only 3 degrees, so I didn’t change the timing chain. I did not replace the lower timing rails.
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I don't want this to sound like I am questioning your work however did you change the three semi-curved rails in the cylinder heads (1 on right head, 2 on left head)? Did you replace the tensioning rail? How did/do the two rails between the cam gears look? Were the covers which clip on to the front of these rails damaged in any way (ie-broken retainer clip)?
Keep us posted.............
