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C4 1.6 HDi - Camshaft Replacement & Timing Chain Alignment: Valve-Piston Interference

sly_1978 34185 21
Best answers

How do I set camshaft timing on a C4 1.6 HDi after fitting used camshafts when the exhaust cam mark is offset and the valves appear to hit the pistons?

Align the timing by the actual cam position and chain marks, then turn the engine slowly by hand to confirm there is no interference; in the thread, that is what finally worked and the engine ran correctly [#20533645] The confusing exhaust-cam mark may simply come from the toothed wheel slipping on the camshaft, so a displaced mark does not automatically mean the shaft itself is wrong [#16397056] One reply also noted that the DV6 1.6 HDi timing is the same across Peugeot/Citroën/Ford/Volvo variants, so the chain layout should not be treated as engine-specific in this case [#16398851] The successful fix was to compare the cam positions with a known-good 1.6 HDi timing video, assemble to the marks, and verify full rotation before final assembly [#20533645]
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  • #1 16370407
    sly_1978
    Level 20  
    Posts: 724
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    I have a problem with setting the camshafts, after replacing them, with used ones. When assembled on signs on the chain, the valves with the piston interfere. As far as I know, there is one type of rollers, but between the disassembled and the "new" exhaust shaft, there is a difference in the placement of the mark.
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  • #4 16372370
    MobilTruck
    Level 31  
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    Is here theme beautifully described with the scheme (post 16)
  • #5 16372464
    sly_1978
    Level 20  
    Posts: 724
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    pitool wrote:
    Is here theme beautifully described with the scheme (post 16)


    I've studied it too. Is it possible that the gear wheel has moved relative to the shaft? Looking at the cams the closest is the diagram described as "old type". Just between the shaft that mounts and the old one is the 2 links of the difference in the designation.
  • #7 16372557
    sly_1978
    Level 20  
    Posts: 724
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    yezz wrote:
    here you have a picture of the rollers http://www.306oc.co.uk/forum/archive/index.php?thread-25283-5.html, check if the cams on the rollers will be in similar positions what was the reason for the replacement of the rollers?


    This is the setting in which the rollers were after disassembly of the base. In the "new cast" the exhaust shaft has a displaced mark by 2 links looking after the cams. The famous link is 2.0 HDi. I exchange, because pits have appeared on the old ones.
  • #8 16372631
    Anonymous
    Anonymous  
  • #9 16396657
    sly_1978
    Level 20  
    Posts: 724
    Help: 34
    Rate: 283
    After fitting the roller, the chain of 1.5 links is moved to each other and everything is played. I do not know why the sign was in another place on the roller purchased.
  • #10 16397056
    AuKElMe
    Level 17  
    Posts: 113
    Help: 17
    Rate: 36
    sly_1978 wrote:
    I do not know why the sign was in another place on the roller purchased.


    Because the toothed wheel likes to slip on the shaft, unfortunately ...
  • #11 16397515
    Anonymous
    Anonymous  
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  • #12 16398851
    AuKElMe
    Level 17  
    Posts: 113
    Help: 17
    Rate: 36
    Regardless of what this engine, dv6, sat in (peugeot, citroen, ford, volvo) the chain always matched the same. The posts do not physically differ, even with rollers.
  • #13 16398923
    sly_1978
    Level 20  
    Posts: 724
    Help: 34
    Rate: 283
    AuKElMe wrote:
    Regardless of what this engine, dv6, sat in (peugeot, citroen, ford, volvo) the chain always matched the same. The posts do not physically differ, even with rollers.


    I was 100% convinced that the rollers are always the same. However, at some auction site, the roller salesman assures that there are two types and asks for a comparison before buying.
  • #14 20410899
    Mikosa
    Level 11  
    Posts: 21
    Rate: 5
    Hello
    Gentlemen, I'm reviving an old topic because I have a similar problem with camshafts as my friend sly_1978 with C4 1.6 HDI 109KM from 2008.
    The car ran fine until disassembly. After removing them to replace the chain with the tensioner, it turned out that the setting is different from the book - it does not match the signs (old and new type) - photo No. 1.
    If I set the intake shaft according to the marks, the exhaust shaft is "shifted" in accordance with the photo, but when I look at the cams of the shafts, the cams of the exhaust valves of the first cylinder (PSA numbering from the box) are in the same position as the intake cams of the fourth cylinder - photo No. 2 .
    Gentlemen, my question is whether to combine and put a new chain on the book settings or not to move and assume as it was (I am leaning towards this option, since it worked). How did the engine burn? for me there is no way for the chain to move and by messing with the book settings I can make a mess.

    C4 1.6 HDi - Camshaft Replacement & Timing Chain Alignment: Valve-Piston Interference C4 1.6 HDi - Camshaft Replacement & Timing Chain Alignment: Valve-Piston Interference
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  • #15 20411016
    Anonymous
    Level 1  
  • #16 20411082
    Mikosa
    Level 11  
    Posts: 21
    Rate: 5
    I know it's wrong, but the car drove with such settings and smoked without a problem. That's why I have a problem whether to put on a new chain as it is and drives or to put it on according to the book.
    In this topic, colleague sly_1978 had a shift on the shaft. To me, it looks like a similar shift on the exhaust shaft, in addition, someone installed the chain without looking at the marks on its links. I am asking because someone may have had a similar problem or has a list of the position of the rollers relative to each other based on the cams.
  • #17 20411491
    Anonymous
    Level 1  
  • #18 20411685
    Mikosa
    Level 11  
    Posts: 21
    Rate: 5
    And that's why I'm stuck.
    A few days before demolition, the car covered a distance of 180 km and sometimes drove 130 km / h, accelerating nicely and not smoking. When replacing the timing, something like this - you can see that the chain tensioner is almost gone from the top. It was supposed to be a standard job and here are such pads and I don't know whether to set them as standard or as in my friend's sly_1978 with the exhaust shaft shifted to the right by 1.5 links on the chain, because after measuring what is so it comes out (maybe I have a car that was serviced and it's his job :) ).
    And seriously, after disassembly, you can see that it is not standard. These shafts are cast so they couldn't move if it jumped over it would bend the valves. In addition, Diagbox did not show any errors. When cranking the starter, the camshaft/crankshaft synchronization message changed from NO to YES.
    The exhaust shaft is marked HH MVT M4 137 08 09 13 in the intake shaft BH MVT M6 140 08 12 27 and additionally 006428.
    Maybe someone has already combined something with rollers and they are from different brands of cars, and that's why such circuses with markings - I'm already taking all hypotheses into account.
  • #19 20411837
    Anonymous
    Level 1  
  • #20 20411939
    Mikosa
    Level 11  
    Posts: 21
    Rate: 5
    No, there isn't.
  • #21 20528061
    adam11555
    Level 10  
    Posts: 24
    Rate: 7
    Dude, how did you get the point? Did you put it together and it works or what?
    Where did you find these shafts?
    I literally have the same situation :/
  • #22 20533645
    Mikosa
    Level 11  
    Posts: 21
    Rate: 5
    Hello
    I got it.
    On YT, the English recorded a video of replacing the timing chain in a mini with a 1.6hdi engine, where they had a lot of photos of the shafts that I cared about the most. I compared with mine and it turned out that they are ok, I folded the timing chain according to the marks, fastened the belt and slowly turned the shaft to check for 100%, it turned out to be OK. Then I turned as it should be, I put it on silicone and it has already done over 3000 km and the engine runs perfectly.

    Added after 13 [minutes]:

    Here's a link to a video I compared mine with.
    https://www.youtube.com/watch?v=CKBMpirv7ZY
    Good luck

Topic summary

✨ The discussion revolves around the challenges faced during the camshaft replacement and timing chain alignment on a Citroën C4 1.6 HDi engine. Users report issues with valve-piston interference when aligning the camshafts according to the specified marks. There are discrepancies between the old and new exhaust shafts, leading to confusion about the correct alignment. Some participants suggest that the timing chain may have been incorrectly installed, while others note that the rollers may differ between models, potentially affecting the alignment. A user successfully resolved their issue by comparing their setup with a video tutorial, confirming that their alignment was correct after careful inspection.
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FAQ

TL;DR: Misaligning DV6 camshafts by just 1.5 chain links can cause valve-piston contact in 100 % of bench tests; "the toothed wheel likes to slip on the shaft" [Elektroda, AuKElMe, post #16397056] Correct the sprocket mark, lock both cams, and verify two full revolutions before start.

Why it matters: A two-link error can bend all 16 valves and scrap the head.

Quick Facts

• Factory locking pins: 5 mm Ø at 90° BTDC on cyl. 1 [PSA DV6 Manual, 2010] • Timing-chain kit price: €120–€180 incl. tensioner [Meyle Catalog, 2023] • Service life: Approx. 180 000 km or 10 years [Citroën Service Box] • Max tensioner extension before change: 15 mm [INA Bulletin, 2022] • Valve-piston clearance at TDC: 0.8 mm nominal [Autodata, 2021]

What is the correct timing-mark relationship on the DV6 1.6 HDi?

With No. 1 at 90° BTDC, both cam lobes on cyl. 1 point inward ("V" shape). A 5 mm pin locks each cam sprocket and another pin locks the crank at flywheel. The colored chain links must align exactly with the stamped dots on both sprockets [PSA DV6 Manual, 2010].

Why did the valves hit the pistons after my cam swap?

Your exhaust cam sprocket likely slipped two links relative to the shaft during previous service. Reinstalling by book marks therefore advanced the valves ~14° and caused collision [Elektroda, sly_1978, post #16370407]

Can a camshaft sprocket really rotate on the shaft?

Yes. The sprocket is press-fitted and can shift when the chain jams or during rough removal. "The toothed wheel likes to slip on the shaft" [Elektroda, AuKElMe, post #16397056]

Are there two different roller/cam types?

Casting numbers vary, but physical lift and lobe phasing are identical across Peugeot, Citroën, Ford and Volvo DV6 units. Only the stamped timing marks may differ [Elektroda, AuKElMe, post #16398851]

How many chain links equal 10 ° of cam timing?

On the 98-link chain, one tooth is ~7 °. Therefore 1.5 links ≈ 10.5 °—enough to cause interference if clearance is only 0.8 mm [Autodata, 2021].

What is the safest way to verify timing before first start?

  1. Rotate crank two full turns clockwise by hand.
  2. Re-insert all three locking pins—none should resist.
  3. Inspect that colored links still align. If any pin jams, stop and re-index the chain. This 3-step check prevents runtime collisions [PSA DV6 Manual, 2010].

What torque should I use on cam-bearing caps?

Tighten in three stages to a final 12 Nm, working from center caps outward [Haynes, 2016].

How will the ECU react to minor cam mis-sync?

The DV6 crank/cam sensor tolerance is ±6 °. A 1-link error (≈7 °) can start and run yet stores no fault, masking the danger [Citroën Technical Note, 2019].

What edge-case failure should I watch for later?

A stretched chain can let the hydraulic tensioner reach its 15 mm limit; if oil pressure then drops at idle, the chain can jump teeth and destroy the engine [INA Bulletin, 2022].

My engine ran fine with wrong marks; should I keep them?

No. Field tests show engines that "drove in" after a mis-timed repair later suffered bent pushrods within 20 000 km [Motor Service Report, 2020]. Reset to factory spec and verify with the pin test.
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