If you have hydraulic lifters, then i wonder if turning the engine over by hand will lift the valve its full amount. The lifter has a ball check valve which shuts when under pressure and effectively turns it (almost) solid, but will this work when turning over by hand, so the valve doesn't lift fully as the lifter drains down?
Don't know if this is what is happening, but just an idea?
Moog
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(o\ /o) '73 GT Beetle with 2.1 WBX (owned since 1990)
(o\ /o) '74 Jeans Beetle (owned since 1986)
(o\ /o) '67 Zenith Blue Beetle (needs lots of work..)
'02 Passat Sport Diseasel Estate ("Das Boot")
'05 Seat Leon FR, chipped (Mrs Moog's toy really...)
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