1.6 engine spins fine for 10 seconds then makes loud grinding noise...

[srgtlord]

So I finally pulled my 1.6 out yesterday and decided it was finally time to discover why when starting the engine and cranking for 10 seconds the starter would spin fine and then stop with a loud grind and a clunk. SO I separated the transmission from the engine and discovered there was no missing teeth on the flywheel starter ring like I expects. There was however a few spots where the teeth looked slightly marred for a few mm . SO the final question would be would slight marring of flywheel teeth cause the starter to bind up? How tight is the tolerance for the starter/ flywheel ring gear?

[TylerDurden]

I'd check the starter bushing in the tranny bellhousing.

[92EcoDiesel Jetta]

I'd check the starter bushing in the tranny bellhousing.

X2

 I made a plug gage so I can feel the wobble in the bushing if worn.

[theman53]

I measured starter bushing and it was .007" bigger than new, but caused it to wear the starter out rapidly. It must be an accurate go/no go gauge for you to check.

[92EcoDiesel Jetta]

I measured starter bushing and it was .007" bigger than new, but caused it to wear the starter out rapidly. It must be an accurate go/no go gauge for you to check.

I made the plug gauge slightly bigger diameter than the starter shaft so I can tell by feel how worn the bushing is. I replaced the bushing.