MK3 Golf 16v piston height engine is not well

[chris_d66]

Hi All,
I have just bought a 96 GTI ABF 16v.
I know it had engine problems bought it as a winter project. The last owner had the timing belt slip and re timed it to find a nice tapping noise and a bit of a knock. I have removed the head stripped down checked the valves springs and looks good.
first thing I noticed dot on the flywheel lines up with centre of the inspection hole but the crank pulley mark and arrow is around 4 degrees out could this be down to the pulley rubber ageing ?.
Second thing number 2 piston seems to sit 3mm lower then the other 3 in the block at TDC unfortunately due to a cracked exhaust manifold with rusted bolts  I did not get chance to drop the sump.
Number 2 piston has a delay on the downward  stroke so hopefully it may be a case of new shells or little end bearings I did fill the bores with oil to stop them going rusty.
Has any one experienced this before with their ABF and was the out come rebuild or replace engine ? also I found the crank position sensor cables twisted and touching together luckily I had a spare one why cant vw make the front engine mount just that little bit smaller so the sensor can be changed easier.

[Len]

Sounds like you have bought a "project" allright!

Well if the timing is out then pistons could be at different heights but two should always be the same.
How are you checking heights? Through the spark plug holes?

What has the sump got to do with exhaust manifold? Not connected!

[thai-wronghorse]

Sounds like you have bought a "project" allright!

Well if the timing is out then pistons could be at different heights but two should always be the same.
How are you checking heights? Through the spark plug holes?

What has the sump got to do with exhaust manifold? Not connected!

i did wonder this myself? 

[Wayne]

If one piston is lower you could have a bent conrod.

[spikenipple]

The only thing I can think of that would make a piston sit lower is either incorrect parts or a bent conrod as Wayne has suggested.

[tweed]

Agree on the bent rod that was my first thought.


The sump and exhaust thing confuses me.
Are you sure its a abf? Does the exhaust go under the sump?

Pictures please.

[chris_d66]

Hi All
Thanks for the reply's and sorry for the confusion.
I had trouble with the exhaust manifold nuts when removing the head and ran out of time yesterday so did not get time to drop the sump.
The pistons were viewed with the head off. number 2 piston is the only one that is not reaching the same height at tdc as the other 3.
The oil I put down the bores has not dropped in the night and now I will not get chance until Saturday to go any further with the engine.

[xionsolaris]

How much did the car cost you

[VW BUSH]

Buy a donor engine with 3 months ticket for a couple of hundred.
Swap it and or build the old one up in your own time.

Think the rusty manifold bolts just took forever to get off so he ran out of time

[chris_d66]

I paid £128.00 for it. Apart from the drivers side sill and engine the rest of the golf has been well looked after.