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I know it sounds obvious but have you checked the cam timing as I think this can have a significant impact.
If the chains have worn and have effectively elongated it can significantly affect cam timing and with good tensioners, particularly hydraulic you will never hear any rattle.
New chains always have an early and rapid amount of elongation as the bed in and while the engine is out it must be worth a quick look.
On the 2.0 FIA engines we build we always use fixed mechanical tensioners so when we hear the chain we know its time to adjust and re-time.
They are a real PITA for initial set up but generally we only adjust them once a year.
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