**UPDATE****UPDATE**
I have had my car in at VW this week, dropped it off Thursday because the chain rattle had come back on mine even though I have had all the latest parts fitted in January last year. (chains, tensioner, guides etc)
Got the call from Ben @ VW Crosshills and he told me the chain and tensioner are fine, they need to look into it further. Got a call about two hours later, they said they think they have found the problem. They said that the magnet piston on the side of the engine that moves the camshaft has a gauze on the end of it, that has come off. They have found it, but they dont know if it has caused any further damage.
They are going to take the head off and have a look and see if their is any damage, if there is they will replace any and every part under warranty. So fingers crossed i get some good news on Monday.
What a sh1t engine the TSi is......
NEW UPDATE - 03/02/2015So it turns out the Gauze on the bearing housing had cracked and come off, luckily is hadn't gone far, it got stuck at the end of the tunnel so was easy to pick out. Martin the head tech at VW Crosshills explained that yet again it is another bad design by VW and there has been two revisions to the bearing housing since 2009.
This is the damage, you can see that 90% of the gauze had gone.
So they replace the bearing bush housing and the magnet (said they have to buy as a set). they were both fitted the next day and all seemed well, no rattle on start up and engine sounded fine. I got about 7 miles down the road and engine management light came on. So I scanned it when I got home and it threw this error code:
1 Fault Found:
000017 - Bank 1: Camshaft A (Intake): Retard Setpoint not Reached (Over-Advanced)
P0011 - 000 - - - MIL ONGoogled it and it came back with a few causes, mainly timing issue. Spoke to Ben at VW and he said bring it back and we will have a look again.
The head tech spend two days looking into and couldn't find an issue with the timing or anything else in the engine. To cut this story short he finally got to the bottom of it. It was caused by the below part not opening and shutting properly, the part is called
Central Valve (for the cam) Part number: 06H 109 257 C. After replacing that the car has been starting and running sweet. So great job by the guys at VW Crosshills again. Cant thank them enough.
I just wanted to post this if anyone else who has had the timing chain done and then the noise comes back 6+ months later.
It will either be the Cam Shaft Magnet Assembly or this little valve thing: