Golf 118TSI - Rattle on Cold Start (camshaft issue!?!)

[vwlovr]

I booked my car at VW Denlo Parramatta. As I dropped the car, I got a service assistant to jump in the car and start it. I was very lucky, the noise came up ! He acknowledged the issue.
2 days later, they told me that the technician could not "replicate" the issue and therefore there was nothing they could do about it !
I went to the dealership to pick-up my car and guess what? As I started it, the noise came up !!!

How could you explain that a "random" noise happen as I drop the car, then pick it up but not during the 2 full days it was at the dealership??? I gave them my car that has a fault, and I expect to pick it up AFTER the issue is fixed, not before !

Apparently the issue is known but it could come from either the left side or the right side of the engine and until a technician can hear which side it is from, they are not going to do any repair.

I also have the shudder issue with the gearbox. They did a firmware upgrade and told me to drive for 500km-1000km... I drove 5km and the issue appeared again !! I have read a lot on the issue and it seems that there might be a fix coming up from VW in mid-december...

[buzuki]

its the camshaft adjuster on the cam. It sticks on cold start up causing that sound. There is a TPI

[Brendan_A]

its the camshaft adjuster on the cam. It sticks on cold start up causing that sound. There is a TPI

So should I be worried? Cause mine makes this noise sometimes on a cold start.

Do you know if it's a big job?

[vwlovr]

Could be indeed, however, it happens to regularly... What do you call a "cold" start exactly ? The noise would appear even 15 minutes after the engine is turned off... Pardon my ignorance, but what is a TPI ?
Thanks a lot for your help,

David

[RW1]

its the camshaft adjuster on the cam. It sticks on cold start up causing that sound. There is a TPI

Yup, TPI - 2009810/18 23.08.2010 is latest edition, replace Part No. 03C 109 088 B, Cam Shaft Positioner if it can be demonstrated the noise is next to the top of the cam chain drive on the top end of the engine. Common problem.

Cam cover off, chain off, inlet cam out, change highpressure fuel pump bucket tappet to change replace Positioner. Fair amount of time like 1/2 day at least.

[mythik]

I can 100% confirm this exact noise will be rectified by TPI - 2009810/18 23.08.2010. Rest easy.

[buzuki]

its bout 6 hours book time, its like doing a timing belt but a chain. And yes it doesnt have to be a dead cold start

[vwlovr]

Thanks guys. The most difficult part of it all is to have the technician hear the noise... any recommendations ?

[buzuki]

LEave it with them, tell them to start it a couple hours later

[vwlovr]

I wish it was that easy... I left it for 2 days and they said they could not hear anything...
Anyway, I'll return my car on Monday and will not pick it up until it's fixed !

Thanks !

[Brendan_A]

I wish it was that easy... I left it for 2 days and they said they could not hear anything...
Anyway, I'll return my car on Monday and will not pick it up until it's fixed !

Thanks !

It's hard to find a good workshop hey?

When mine gets that bad I may just pay my VW specialist to do it. Only person I trust working on my car.

[Bel]

I get clicking when I put my foot down a bit when I am already doing 90+kms... say on the fwy in traffic and I want to overtake... weird as can be.

[Mr T.]

Had my 2009 Golf TSi cam shaft fixed today. Had the same sound after start occur for a few months... took it to South Yarra - they had no idea and the to Barlo in Glen Waverley whereby I showed them my video clip and knew exactly what it was. The drive feels 'torquey' and good. Fingers crossed this a once off, and not related to me driving in DSG mode like a maniac.

[RW1]

Had this noise start occurring in January after I posted the VW Bulletin number on this topic last November. Decided I wasn't having the engine ripped apart and tackled it a different way. I seems the Camshaft Adjuster Control Solenoid gets gummed up and cannot operate properly.

Made a little tool up for the 1.4Tsi consisting of a connector to fit the Camshaft Adjuster connection on top of the engine and a repair wire split in two. Repair wire end fittings fitted into the connector shell. Wire cut in half and two long wire extentions fitted to reach the battery.

The Camshaft Adjuster Control Solenoid unit is not polarity sensitive. So I pulsed the Camshaft Adjuster Solenoid with 12 volts from the car battery. (ON pulses about 0.25 seconds duration, OFF for 0.5 seconds) Pulsed the Solenoid 15 times, then reversed the battery connections and did the same again. Did this with the engine very warm as cold oil would dampen the full operation, about 15 minutes after the engine being stopped, so pretty warm when done. The effect of the pulsing took about 10 cold starts to clear the noise down fully but even after the first start, there was a significant reduction in noise. Camshaft Adjuster noise has now gone and the same comment as above, more torquey and smooth as the Adjuster is now getting oil pressure properly controlled by the engine ECU.

The tool parts are:

- Connector body - 1J0 973 702, £2.05 + VAT
- VW Repair Wire - 000 979 131E, £1.99 + VAT (Cut in half to make two short wire ends.)
- Then crimp on extension wires to reach over to the car's car battery.

(Prices are UK but it gives an idea of cost.)

This is the special tool made up in its final form.



The Camshaft Adjuster Solnoid Valve has a resistence of 7.4 Ohms and at 12.25 volts from the battery that meant 1.66 amps would be flowing in the wires. I thought using the car battery was a little different from using a small battery like the PP3 (which didn't cure the problem when tried). So for safety, it called for a proper tool to be made, as the Adjuster Solenoid is about £80 here in the UK.

This is the tool connected to the 1.4TSi engine Camshaft Solenoid connection on top of the engine once the engine cover is off.



This is how the Adjustable Camshaft works. This may be Honda but the design of the Adjuster and Solenoid valve are identical. K-Series iVTEC VTC Cam Phasing System - In Depth - YouTube

As my engine only does short runs of 5 miles most of the time, the final part is to clean out the Camshaft Adjuster and Control Solenoid area with Forte engine flush today as part of changing my oil at the 6 month interval change I do additionally to VW servicing.... Clean engines internally and provide anti-wear protection

[cktsi]

Great thread and top tips! I thought i was the only one with this issue. The bitch is trying to getting the problem to replicate in front of the dealer as everyone here has noted.