TSI Amarok engine/turbo noises

[EZZA]

Chasing a couple of noises on my TSI Amarok. Coming up to 150,000km and is stage 1 APR tuned.

1. First is a rattle sound that I can hear on acceleration between roughly 1800rpm-2500rpm. Thought at first it was the suitcase muffler as that rattled when I moved it but have had it replaced with a Lukey and noise is still there. Also thought maybe the wastegate actuator rod may have caused the rattle but it appears to have no play plus this is the k03 turbo which VW tech I asked to buy the actuator clip from said didn't have that issue. Also explored the possibility of it being the clutched alternator pulley but this appears to be fine also on inspection.

2. Second issue is after a long downhill coast off throttle when I begin to accelerate I get a loud screeching sound for a second or two that appears to be turbo related. From the reading I've done this morning I may have a blown exhaust manifold gasket but will have to have a closer look to confirm.

Anyone had similar issues to the above or have any ideas of what it may be?

[Lucas_R]

For the sake of a very small sum of money, you may as well try the turbo actuator clip as a fix for issue #1. Assuming the turbo on your engine is the same as the one from a Mk6 Golf GTI then they do suffer from a rattle on the turbo wastegate rod and the clip fixed about 90% of the noise in my case (fixed it enough that you couldn't really hear it anymore).

Cant help you much with issue #2 i am sorry. But I would have thought if you had a blown manifold or dump pipe gasket that it would not be making a screeching noise, but more of a farty exhaust leaking kind of noise. Screeching in my experience is more likely to be a boost leak so perhaps have a good look around your intercooler pipes for hairline cracks, and check your hose clamps incase any have come loose over time. Also check your PCV on the top of the cam cover as when these fail it can cause a screeching noise.

[EZZA]

Thanks for the reply Lucas. Apparently turbo is very similar to K03 in GTI but slightly different design. I'm assuming the wastegate actuator is the same so the clip would most likely fit.

I agree about the exhaust leak until I watched a video online (IMG 3829 - YouTube) which is exactly the noise I get at times. I also found this while having a quick look at lunch, not was I was hoping to see..... it appears stud #5 has gone MIA!!

[Sharkie]

Chasing a couple of noises on my TSI Amarok. Coming up to 150,000km and is stage 1 APR tuned.

2. Second issue is after a long downhill coast off throttle when I begin to accelerate I get a loud screeching sound for a second or two that appears to be turbo related. From the reading I've done this morning I may have a blown exhaust manifold gasket but will have to have a closer look to confirm.

Anyone had similar issues to the above or have any ideas of what it may be?

At what revs and in which gear(s) does this happen? It may just be the known issue with the PCV return opening into the turbo inlet.

[Sharkie]

Does it sound similar to the whistle you can hear here?

Amarok TSI Boost - YouTube

[EZZA]

Does it sound similar to the whistle you can hear here?

Amarok TSI Boost - YouTube

Hi mate, definitely not the PCV whistle as I have that since APR tune like yours. This is a screeching noise more like a belt screech, it's hard to explain but in higher gears (3rd-4th-5th) when rolling down long hills off throttle when you get back on the throttle even lightly it makes this horrible screech for a second or two and then goes away. I think the exhaust manifold gasket must be blown out as I just discovered a missing stud (pic above).

Like this:
IMG 3829 - YouTube

[EZZA]

So just an update on this, got the car back from workshop over the weekend with the broken stud drilled out and a new one helicoiled in it's place. Was a prick of a job to drill out apparently as the exhaust manifold studs actually sit at a 45 degree angle to the head. Had a new gasket fitted also and noise is gone. Feels a lot more responsive down low coming onto boost now without the leak and i'm pretty sure it idles better too.
Next will be complete timing chain kit as mechanic informed me that my engine even though it's a late revision TSI still runs the old style tensioner which has a habit of letting go prematurely.

[Sharkie]

So just an update on this, got the car back from workshop over the weekend with the broken stud drilled out and a new one helicoiled in it's place. Was a prick of a job to drill out apparently as the exhaust manifold studs actually sit at a 45 degree angle to the head. Had a new gasket fitted also and noise is gone. Feels a lot more responsive down low coming onto boost now without the leak and i'm pretty sure it idles better too.

Good that its sorted. Got to love weird noises on cars.

Next will be complete timing chain kit as mechanic informed me that my engine even though it's a late revision TSI still runs the old style tensioner which has a habit of letting go prematurely.

And after that perhaps an AWD conversion .... interesting to note on the tensioner, I will have to look at mine, our specialist VW shop has not mentioned anything on that to me before.

[EZZA]

Update on the manifold stud. I thought it was done and dusted but just before the end of last year the noise after a long coast downhill came back. Upon inspection I could see the nut was missing from the same stud that was repaired last time and the end of the stud appeared to be missing. So after just over 1.5years the helicoil (which wasn't done properly by first mechanic) has let go which caused the stud to pull out a bit and the nut & end of stud to leave the chat.
So in the end I took it to my preferred Mechanic who had a thread doctor guy come out and remove + repair + replace the helicoil. Mechanic was able to replace this stud and 2 of the other ones also. Hopefully won't have to deal with the issue again for a while!