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Valve Gear, Servicing Audi S6 C5

Mechanical 1 illustration ~579 words
CAUTIONDO NOT re-use fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
CAUTIONAfter working on valves, do not start the engine for about 30 minutes, otherwise the valves will strike pistons. Turn the crankshaft two complete revolutions by hand before starting engine.

Note. Cylinder heads with cracks between valve seats or between valve seat inserts and spark plug threads can continue to be used without reduced service life, if the cracks are not wider than 0.3 mm (0.012 in.) or when no more than 4 turns of the spark plug threads are cracked.

The following list pertains to see scheme 154.

  1. Double bearing cap Lightly coat with sealant AMV 100 001 02. See «BEARING CAP, APPLYING SEALER»(ref-196260-S40111167762006042100000) .
  2. Bolt, 10 Nm (7 ft lb)
  3. Hydraulic valve lifter Removing and installing, see «VALVE STEM SEALS, REMOVING AND INSTALLING»(ref-196260-S31359619432005100700000) Do not interchange. Lubricate contact surface with oil.
  4. Exhaust camshaft Check axial play. See «CAMSHAFT AXIAL PLAY, CHECKING»(ref-196260-S14735088622005100700000) . Removing and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000) Check radial clearance using Plastigage (lever removed): Wear limit: 0.1 mm (0.0039 in.) Max. run-out: 0.01 mm (0.0004 in.)
  5. Intake camshaft bearing cap Note installation position and numbering. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000) . Observe dowel pin.
  6. Exhaust camshaft bearing cap Observe dowel pin. Note installation position and numbering. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000)
  7. Bolt, 10 Nm (7 ft lb)
  8. Double bearing cap
  9. Cap Always replace To remove: remove bearing cap. With cap installed, lightly drive in with 3202
  10. Bearing cap Before installing, lightly coat with sealer AMV 100 001 02. See «BEARING CAP, APPLYING SEALER»(ref-196260-S40111167762006042100000) CAUTION: Part numbers are listed for reference only. Always check with your Parts department for latest information.
  11. Valve roller lever for exhaust camshaft
  12. Drive chain Installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000)
  13. Valve roller lever for intake camshaft
  14. Intake camshaft Check axial play. See «CAMSHAFT AXIAL PLAY, CHECKING»(ref-196260-S14735088622005100700000) . Removing and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000) Check radial clearance using Plastigage (lever removed): Wear limit: 0.1 mm (0.0039 in.) Max. run-out: 0.01 mm (0.0004 in.)
  15. Bolt, 10 Nm (7 ft lb)
  16. Mechanical camshaft adjuster With valve for camshaft adjustment -N205- Before removing, secure with 3366 bracket tensioner. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000) .
  17. Rubber/metal seal Always replace.
  18. Valve keepers
  19. Valve spring plate
  20. Valve spring
  21. Valve stem seal Replacing, see «VALVE STEM SEALS, REMOVING AND INSTALLING»(ref-196260-S31359619432005100700000)
  22. Seal Always replace.
  23. Cylinder head See note under «VALVE GEAR, SERVICING»(ref-196260-S22049538912005100700000) . Valve guides, checking, see «VALVE GUIDES, CHECKING»(ref-196260-S00869434022005100700000) . Valve seats, reworking, see «VALVE SEATS, REFACING»(ref-196260-S25890004892005100700000) .
  24. Exhaust valve Do not rework, only lapping is permitted Valve dimensions, see «VALVE DIMENSIONS»(ref-196260-S03352175062006042100000) . Valve guides, checking, valve seats lapping, see «VALVE GUIDES, CHECKING»(ref-196260-S00869434022005100700000) .
  25. Intake valve Do not rework, only lapping is permitted Valve dimensions, see «VALVE DIMENSIONS»(ref-196260-S03352175062006042100000) . Valve guides, checking, valve seats lapping, see «VALVE GUIDES, CHECKING»(ref-196260-S00869434022005100700000) .
  26. Seal For intake camshaft Removing and installing, see «OIL SEAL FOR RIGHT CAMSHAFT POSITION (CMP) SENSOR, REMOVING AND INSTALLING»(ref-196260-S37519141862005100700000) and «OIL SEAL FOR LEFT CAMSHAFT POSITION (CMP) SENSOR, REMOVING AND INSTALLING»(ref-196260-S39713225362005100700000) .
  27. Rotor for Camshaft Position (CMP) sensor Note position
  28. Rotor for Camshaft Position (CMP) sensor
  29. Washer Conical
  30. Bolt, 23 Nm (17 ft lb)
  31. Camshaft Position (CMP) sensor -G40
  32. Bolt, 5 Nm (44 in. lb) + 90°
  33. Shaft for valve roller lever, intake side
  34. Bolt, 9 Nm (80 in. lb)
  35. Bolt, 9 Nm (80 in. lb)
  36. Shaft for valve roller lever, exhaust side
  37. Bolt, 55 Nm (41 ft lb)
  38. Camshaft sprocket
  39. Seal For exhaust camshaft Removing and installing, see «CAMSHAFT OIL SEALS, REMOVING AND INSTALLING»(ref-196260-S15787137932005100700000) .
  40. O-ring For valve roller lever shaft

Scheme 59

Scheme 59: Valve dimensions
Scheme 59: Valve dimensions

Note. Do not reface valves. Only hand-lapping is permissible.

DimensionIntake valveExhaust valve
Diameter -a28.8-27.0 mm (1.055-1.063 in.)29.8-30.0 mm (1.173-1.181 in.)
Diameter -b5.96-5.97 mm (0.2346-0.2350 in.)5.94-5.95 mm (0.2339-0.2343 in.)
Length -c104.84-105.34 mm (4.1276-4.1472 in.)103.64-104.14 mm (4.08093-4.1000 in.)
Angle, alpha45°45°

VALVE DIMENSIONS

WARNINGSodium-filled exhaust valves must not be scrapped until they have been properly treated as follows: Saw valves in two sections using metal saw at a point between the center of the valve stem and the valve head. The valves must not come into contact with water when this is done. Throw the valves into a bucket of water (not more than 10 at a time) and step back. A sudden chemical reaction will occur during which the sodium filling burns. After this treatment the valves can be scrapped normally.

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