2000 AUDI A8 AHA ATQ Engines Valve Gear Service Manual

15-43


Valve dimensions

WARNING!
Valves must not be refaced by cutting or grinding.Only hand lapping is permitted.Dimension
Intake valve
Exhaust valve
Diameter -a- 26.8 - 27.0 mm
(1.055 - 1.063 in.) 29.8 - 30.0 mm
(1.173 - 1.181 in.)
Diameter -b- 5.96 - 5.97 mm
(.2346 - .2350 in.) 5.94 - 5.95 mm
(.2338 - .2342 in.)
Length -c- 104.84 - 105.34 mm
(4.1275 - 4.1472 in.) 103.64 - 104.14 mm
(4.0803 - 4.0999 in.)
Angle -a-
45
45
Pa
ge 49 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

15-44

WARNING!

Sodium-filled exhaust valves must not be
scrapped without first being properly treated.
The valves must be cut open using a
hacksaw, by hand, between the valve head
and the middle of the stem.
The valves must not come into any contact
with water while being cut.
After cutting open the valves, throw not more
than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.
Valves that have been treated in this way can
be disposed of as normal waste.
Pa
ge 50 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

15-45

Hydraulic valve lifters, checking


CAUTION!

After installing new hydraulic valve lifters the
engine must not be started for about 30
minutes. The hydraulic valve lifters must
settle (otherwise valves will strike pistons).
Then turn crankshaft two full revolutions by
hand before starting.

Notes:

Only replace hydraulic valve lifters in complete
sets. Hydraulic valve lifters cannot be adjusted
or repaired.
Irregular valve noise when starting engine is
normal.

- Start engine and let run until coolant
temperature reaches at least 80 C.

- Increase RPM to 2500 for about 2 minutes. If
necessary, test drive vehicle.
If hydraulic valve lifters are still loud, locate faulty
valve lifter as follows:

- Remove cylinder head cover.
Pa
ge 51 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

- Rotate crankshaft clockwise by turning mounting
bolt for toothed belt sprocket until lobes on
camshaft of hydraulic valve lifters to be checked
are pointing upward.

- Measure clearance between cam and valve
lifter.
Pa
ge 52 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

15-46


Note:
If irregular valve noise occurs repeatedly during short journeys and
disappears after extended driving, the oil check valves must be replaced
page 17
-9 . - Push down on valve lifters using wood or plastic wedge. If 0.20 mm
(0.008 in.) feeler gauge can be inserted between camshaft and valve
lifter, replace valve lifter.
Pa
ge 53 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

15-47

Valve stem oil seals, replacing


Cylinder head installed
Lock carrier in service position page 13
-1

- Remove ribbed belt page 13
-8 .

- Remove toothed belt page 13
-12
.

- Remove camshafts page 15
-31
.

- Remove valve lifters (do not interchange) and
lay aside with contact surface facing down.

- Remove spark plugs.

- Move piston for individual cylinder to Bottom
Dead Center (BDC) position.

Note:
Lightly tap valve lever to loosen stuck valve
keepers.

Exhaust side

Note:
Pa
ge 54 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

Before attaching the adjustable rod, remove the
two studs in the center of the cylinder head and
the three upper studs (intake side) for mounting
the cylinder head cover.

- Install VW653/3 pressure hose together with
seal hand tight into spark plug hole of relevant
cylinder and apply constant pressure (at least 6
bar).
Pa
ge 55 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1

15-48


- Attach 2036 adjustable rod (as shown in figure) using M6 x 40 bolts
with large washers.
- Remove valve spring using VW541/1 lever and VW541/5 valve spring
tensioner.
- Remove valve spring and valve spring plate.
- Remove valve stem oil seal using 3047A slide hammer.

- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly lubricate sealing lip with oil.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3129
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
Pa
ge 56 of 62 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.15.1