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All springs were found to be in normal condition (Figure 4).

1 intake valve was found to be broken while 1 intake valve and 2 exhaust valves were found to
be unbroken (Figure 5). No significant oil deposits were found on all valves. All valve stems
were in normal condition (Figure 6). The unbroken intake valve was inspected and minor pitting
was found on the unloaded sloping area and the loaded area (Figures 7-9). The exhaust valves
were found to be in normal condition (Figure 10).
The broken intake valves was inspected. Fatigue marks could clearly be seen at the damaged
area (Figure 11). The cracked area was closely inspected and no further details could be found
as the crack initiation site was burned off (Figure 12). Upon further sectioning, 2 additional
fatigue cracks were found (Figure 13). Both cracks were closely inspected and no further details
could be found (Figures 14-16). Multiple cracks were found on the unloaded sloping area
(Figure 17). One crack was opened via forced fracture and multiple fatigue cracks were found
(Figure 18-20).
4. EVALUATION
It is clear that the cause of the abnormal noise was due to the damaged intake manifold and
cylinder head. The damage to the manifold was caused by a blowby of exhaust gases through
the broken intake valve.
Although multiple fatigue cracks were observed on the valves, no clear surface damages could
be found at the initiation areas. This could be due to the cracks originating from small pits which
were subsequently eroded away, or that the fatigue had initiated due to loading condition.
It is not possible to determine the exact cause of the failure based on the indications available.
Possible causes for the failure could include corrosion pitting, breakdown of the coating layer on
the valve head due to localized hot spots, or high loads due to valve clearance settings or valve
head geometries.

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6. FIGURES / PICTURES

Figure 1: A6 cylinder head received

Figure 2: Damaged intake valve

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Figure 3: Deep circular groove on the top of all valves

Figure 4: All springs in normal condition

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Figure 5: 1 broken valve, 3 unbroken valves

Figure 6: All valves stems in normal condition

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Figure 7: Unbroken intake valve

Figure 8: Minor pitting on unloaded face

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Figure 9: Minor pittingon loaded area

Figure 10: Exhaust valves in normal condition

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Figure 11: Clear fatigue marks on broken valve

Figure 12: Fatigue marks, crack initiation site burned

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Figure 13: Additional fatigue cracks seen on further sectioning

Figure 14: Fatigue marks, crack initiation site burned

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Figure 15: Fatigue marks, crack initiation site covered by folded metal

Figure 16: Opposing crack surface showed no significant details

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Figure 17: Multiple cracks on unloaded area of crack valve

Figure 18: Multiple fatigue marks found

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Figure 19: Fatigue crack initiation site

Figure 20: Fatigue crack initiation site

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