This TSB involves all 2008-2010 VW models equipped with the 2.0L engine. Customers may complain about a rattling noise in the engine compartment/exhaust area while accelerating from 1,800 to 3,000 rpm.
In order to complete proper diagnosis to determine if the noise is coming from the turbocharger, use the following procedure.
1. Ensure that there is no physical internal or external damage to the turbocharger. If damage is observed, continue diagnosis and repair as necessary. If no damage is observed, proceed to Step 2.
2. Test drive the vehicle to duplicate and to familiarize yourself with the noise. Noise can typically be duplicated by driving up a moderate incline, beginning at 35 mph in fourth gear (manual or automatic) and accelerating through the rpm range of 1,800-3,000 rpm under moderate to heavy throttle.
3. Once you have confirmed the noise, attach a two-ounce wheel weight to the wastegate actuator rod and perform another test drive. If after attaching the weight to the actuator rod, the noise diminished or has changed in pitch, DO NOT replace the turbocharger. Remove the weight, create a VTA ticket in ElsaWeb and contact the VW Technical Helpline at (800) 678-2389. If, after attaching the weight to the actuator rod the noise has not changed, remove the weight and continue diagnosis and repair as necessary.
NOTE: Although the noise may be originating from the turbocharger, it can be amplified through resonance to the catalytic converter and be mis-diagnosed as a loud converter. Because of exhaust gas pulsations, the wastegate flap and actuator rod vibrate at the introduction of boost pressure.