Engine noise after timing chain tensioner replacement

OK. Here's the story. 2008 Sequoia 5.7 with 248K. I bought it with 145K about 5 years ago and had a misfire code 3 or 4 times over the course of that time. Always at WOT at or near redline. Every time it went into limp mode. Shut it down and restart the engine and it runs normal again until the next time. These were very isolated incidents oftentimes many months apart. I pulled the plugs to check them and one of them had lots of oil leaking down the tube. A couple of others had some but the 3rd from the firewall on the PS was bad. Changed plugs and kept driving until I could get around to changing the spark plug seals. This truck was our family vehicle and my wife's daily but as 3 of the 5 teenagers were now driving, we almost never went anywhere together in the Sequoia. So for the past year and half to 2 years it has been very infrequently driven.

This past spring, I finally took the DS valve cover off to start doing the valve cover gaskets and plug seals. When I got it off and was marveling at how clean and beautiful the top of the engine was for the age and mileage, I realized that one of the roller rockers was just laying in the head. Just laying there minding it's own business. WHAT?!?!?!? With the rare exceptions noted earlier, the truck ran great! So now I'm pulling the cam tower so that I can get the roller rocker and cap installed again. Pulled the other side and everything was in its place. The cam tower was sealed with a dark brown looking gasket material so I'm thinking someone had been in there to fix a cam tower leak before I got it and they just knocked that roller rocker off while re-installing. I know I knocked a bunch of them off in my first few attempts to reinstall the cam tower.

In the process of removing the cam tower, I came to realize that the main tensioner on the DS chain was very weak. Good grief. Now I'm pulling the whole timing cover. All of this is lots of fun and it's made so much better by the fact that I'm trying to do this job a couple of hours at a time whenever I can get free to go work on it. Sometimes two, three, or four weeks would go by and I wouldn't even get to lift the hood.

So I got the timing cover pulled, put the new tensioner in and resealed and reinstalled the cam tower with all new o-rings and seals up top. I lined up the orange timing chain marks on the dots on the crank and got the yellow marks lined up with the marks on the cams on both sides. I watched a lot of videos to make sure that I was doing that right. The other night I finally got everything put back together and started the truck up. It made a horrible clattering sound for about 5 seconds and then settled into an unsteady idle while the ECU tried to figure things out. No codes and the noise seemed to pretty much go away. I drove the truck a little bit that night just to see how it would do. All good. The next day I drove it to work and after another loud start up it seemed fine. Tons of power, no codes and smooth sailing for 15 miles or so on the interstate. When I got off the interstate and stopped at the first stop light, I noticed a pretty loud "ticking" noise that seemed to be coming from the DS of the engine. I will upload a video that I took of the truck running in my garage but I will also describe it here. It is definitely coming from the DS up top. It is engine speed dependent and seems to get louder as revs increase. I used a breaker bar to listen to different areas of the engine and confirmed that it is on the DS but I'm really struggling to locate it more precisely than that.

Here's what I've done to troubleshoot so far:
- pulled the plugs to make sure that we reinstalled them properly and that they are properly gapped. Plugs and coils appear good.
- pulled the oil filler tube with the engine running and looked down at the tensioner to see if I could see it jumping. Rocksteady.
- filled up with gas to try to dilute what was in the tank just in case some water had condensed in there or whatever.
- checked the oil level. Good to go. I have used Havoline 5W20 and Wix/Napa Gold filters the entire time that I've owned the truck.

I hear a lot of people complaining about various types of noises that these engines make but I really don't recall this one ever sounding even remotely like this. I can't wrap my head around something being badly wrong without setting a trouble code but I suppose it's possible.

I'm open to all suggestions, questions, criticisms. There's a ton of knowledge and experience on here. If you've read this far and don't have anything to add, thanks for your time anyway.

 

https://www.dropbox.com/s/7nowj05g0q9rqih/IMG_0811.MOV?dl=0

It’s a big file. Let me know if you have trouble opening it and I will go try to get a shorter one.

 

I think I would be pulling the valve cover on that side and checking out the chain tension and looking for anything out of place.

 

What was the problem ? I have the same noise after a brand new timing chain and tensioners installed. I hope you can help me out

 

He ain't been around since 2021, brother.. Might as well start a new thread and copy his description if it fits.