2.0 FSI GT -engine rattle noise

[trigolf]

Hi,

My 2005 Golf 2.0 GT FSI - not GTI, has ,for several months, been making a strange metallic rattling noise which increases with engine speed. It is most noticeable when pulling away from rest or accelerating and is very noticable. At speeds over 45 mph it becomes inaudible.It has been checked over by three different garages ( including an independant VW specialist)and they cannot find what the problem is !
The exhaust/heatshields/cats have been checked and also the engine mounts. The entire DMF and clutch assembly has been changed, as diagnosed by one garage, but the fault remains. The cam chain and tensioner has been replaced, as well as the balancer unit chain and tensioner in the sump and the fault remains. The car has not thrown up any fault codes either. The big ends and main bearings were also checked when the sump was dropped and nothing was amiss. The car has done 65,000 miles and drives perfectly other than this stupid noise - which is doing my head in now! Anyone got any ideas ?

[th3_f15t]

Does it do it at idle? If so, does it sound like it's inside the engine or a part attached to it?

A random suggestion, but has the heat shield on the airbox/engine cover been checked?

[markos]

my rattle turned out to be the plastic air intake... might be worth checking that out

[th3_f15t]

my rattle turned out to be the plastic air intake... might be worth checking that out

Yay! I may of said something not stupid!

[trigolf]

Markos,th3_f15t

 It doesn't do it at idle. Engine cover has been checked. Air intake - Good suggestion, Can you be more specific - i.e. any particular part of the air intake?

[th3_f15t]

The intake scoop is fixed by two screws below the slam panel, little fiddly but manageable with patience. Then the air box itself is bolted onto the bottom of the engine cover. The two are connected by a flexi pipe only a few inches long.

[tonsta31]

Hi really sorry to bring up and old thread but I have EXACTLY the same issue, as strange knocking/tapping noise when underload accelerating or just pushing the pedal to the floor. if the revs are up the noise is not present, also if im driving changing from higher revs the noise is not there.

Been checked by four garages now and none can find the issue. One place there was a small blow from front pipe/manifold.

Really stumped as everything has been suggested from cam tensioner to internal engine parts.

Would love to know if you sorted the noise so I know where to start!

Thanks