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05 Rolla has timing chain? Not belt? Just asking.
Anyhow. Here's my 2 cents.
Whatever you have, belt or chain, that type of cold start noise is typical of what is generally called tining chain/belt slap.
Yes, I did see that you replaced tensioner.
But here's the thing.
1. either belt or chain stretch, resulting in slack and becoming source for slap.
2. tensioners, in whatever form, spring or hydraulic, seize functioning properly over the time. Either the spring stretched or tensioner does not have ratcheting mechanism to prevent it from recessing itself back into its housing overnight or, oil pressure takes time to build up in tensioner, resulting in slapping belt/chain.
Keep in mind that engine is a large metal object conducting sound very well and engine bay is excellent resonator, deceiving where noise is coming from.
Also, slack in belt/chain WILL result in off camshaft position, what WILL result in rockers slap, what WILL sound across pretty much entire engine.
Now, AS ENGINE WARMS UP AND OIL PRESSURE BUILDS UP, tension on the belt/chain restores to where it should be - et voila, noise is gone.
My suspicion is - you have oil passages clogged for whatever reasons, retarding oil pressure build up, resulting in what you read above.
That's my dos centavos, based on dozens of videos of various engines having just that - timing slap.
Now, what remedy do I recommend? Seafoam engine. Twice. Son had horrendous cold start up racket on Nissan V6 engine. We fixed it with one Seafoaming, it came back few months later, second Seafoaming - was good till he sold the car. Also, you got to watch dem oil level and oil changes.
Last edited by ukrkoz; 05-16-2019 at 10:31 AM.