I got the car back with a fresh tensioner, didn't do a thing.
So, it sounds like I'm one of the LUCKY ONES with a "non-heat treated" timing chain.
Jeepers it sounds bad.
One thing is for sure though, the sound insulation on these Cobalts is amazing as it's barely audible with the windows up, and sounds like train wreck when there down.

Sorry to hear that you have to have what mine needed. I hope they know how to time it right. They can be fun to try and time :).

Sorry to hear that you have to have what mine needed. I hope they know how to time it right. They can be fun to try and time :).

Yeah, I'm not to fussy about them pulling the timing set apart when the engine is so new, but if its gotta be done, its gotta be done. I assume they replaced the gearset on yours aswell as the chain eh?:)

Wait, can you explain what happened to need to have this done? Since both our cars were built around the same time I'm wondering if I should look out for anything.

Wait, can you explain what happened to need to have this done? Since both our cars were built around the same time I'm wondering if I should look out for anything.

I'm with him, what causes this and how do we know if we are in the same boat!

Wait, can you explain what happened to need to have this done? Since both our cars were built around the same time I'm wondering if I should look out for anything.

Sorry about that. I'd posted earlier in this section concerning the problem so I didn't want sound like a broken record.
At any rate, Pyros777 I remember when we both received our Balts. :)
The problem is this: @ 3000-4000RPM, the engine emits a rattle/chirp that is not only anoying, it makes the car sound like a peice of junk. As mentioned, you will hear the sound quite easily with your windows down and adjacent to a barrier of some sort (schrubs, divider etc). Put your car in neutral and rev the engine in that range. You'll know it if you've got the problem or not.
Apparantley (thanks to another post), GM received a bad batch of timing chains. The rollers lack hardness and fail. The remedy is full replacement of the timing set (chain and gears).
My dealer is currently checking with GM to rectify the problem.
I'll keep you posted.