• 
  [*]ALL DATA IS FOR A CINQ BUT SHOULD APPLY TO SEI'S WITH THE EXCEPTION OF MPI INJECTION COMPONENTS
  

• OHV relates to the 899cc engine.
• OHC relates to the 1108cc engine

Fluids:

• OIL:
• Multigrade engine oil, viscosity SAE 15W/40to API SG and/or CCMC-G4
• (plenty use 10W/40 in cinqs/sei's though)

Coolant:

• Ethylene glycol based antifreeze

Manual transmission:

• SAE 80 W EP gear oil to API GL4 and or MIL-L-2105

Braking system:

• Hydraulic fluid DOT 4 minimum

Tyre pressures

• Normal load
  
• 145-70-13
• Front & rear
• 2.0 bars (29psi)
  
• 165-55-13
• Front & rear
• 2.1 bars (30psi)
  
• Full load
  
• All models 2.2 bars (32 psi)

Capacities

• Engine oil inc filter OHV= 3.75 litres OHC=3.47 litres
• Cooling system OHV=4.8 litres OHC=4.0litres
• Transmission OHV/OHC=2.4 litres
• Washer fluid reservoir OHC/OHV=1.8 litres
• Fuel tank OHC/OHV= 35 litres

Engine

Oil filter type

• OHV champion C135
• OHC champion F107
  
• OHC valve clearance
• Inlet 0.40 +/- 0.05mm
• Exhaust 0.50 +/- 0.05mm

Fuel system

Air filter

• OHV champion U521
• OHC champion U647

• Fuel filter champion L201

• Engine idle speed
• OHV 850 +/- 50RPM
• OHC 900 +/- 50RPM

Exhaust gas CO content @ tailpipe

• OHV < 0.50%
• OHC < 0.35%

Ignition system

Spark plugs

• OHV champion RN9YCC 0.8mm electrode gap
• OHC champion RN9YCC 0.9mm electrode gap

(gaps relate to champion recommendation, for other makes refer to the makers information)

Clutch

Pedal travel

• OHC(sporting) models 120 +/- 5mm
• OHV models 110 +/- 5mm

Brakes

Friction material minimum thickness

• Front pads 1.5mm
• Rear shoes 1.5mm

• Torque wrench settings
• Alternator securing bolts 49nm/36lb/ft
• Exhaust manifold
• OHV 20nm/15lb/ft
• OHC 28nm/21lb/ft
• Exhaust front pipe to manifold 18nm/13lb/ft
• Inlet manifold
• OHV 20nm/15lb/ft
• OHC 28nm/21lb/ft
• Road wheel bolts 86nm/63lb/ft
• Spark plugs 27nm/20lb/ft
• Transmission filler/level plug 25nm/18lb/ft
• Transmission drain plug 45nm/33lb/ft

OHV engine specs and torques

• Engine code 1170 A1.046
• Capacity 899cc
• Nominal bore 65.0mm
• Stroke 67.7mm
• Compression ratio 8.8 : 1
• Max power 29KW @ 5500RPM
• Max torque 65NM @ 3000RPM
• Firing order
• 1-3-4-2
• No 1 located at timing chain side of engine

Torque settings

• Camshaft sprocket bolts 45nm/33lb/ft
• Crankshaft pulley bolt 50nm/37lb/ft
• Crankshaft pulley bolt 100nm/74lb/ft
• Cylinder head bolts
• Stage 1 30nm/22lb/ft
• Stage 2 angle tighten 90o
• Stage 3 angle tighten another 90o
• Flywheel 45nm/33lb/ft
• Flywheel lower cover bolts 10nm/7lb/ft
• Front left hand engine mounting bracket to transmission 25nm/18lb/ft
• Front left hand engine mounting through bolt to nut 50nm/37lb/ft
• Front left hand engine mounting flange to bodyshell 25nm/18lb/ft
• Rear engine mounting bracket to diff case (M12 bolts) 85nm/63lb/ft
• Rear engine mounting bracket to diff case (M10 bolts) 70nm/52lb/ft
• Rear engine mounting flange to bodyshell 25nm/18lb/ft
• Rear engine mounting through bolt to nut 50nm/37lb/ft
• Right hand engine mounting, through bolt to night 50nm/37lb/ft
• Right hand engine mounting, flange to bodyshell 25nm/18lb/ft
• Rocker cover 8nm/6lb/ft
• Rocker shaft pedestal nuts 40nm/30lb/ft
• Sump 10nm/7lb/ft
• Timing chain casing bolts 8nm/6lb/ft

Cylinder head

• Valve seat angle 45o 0’ +/- 5’
• Valve guide to bore in cylinder head
• Inlet & exhaust 0.033 to 0.080mm (interference fit)

• Valves
• Valve stem diameter 6.982 to 7000mm
• Valve face angle 45o 30’ +/-5’
• Valve face width 2.0mm
• Valve stem to guide clearance 0.022 to 0.058mm

Rocker gear

• Rocker shaft diameter 14.978
• Rocker shaft to rocker arm clearance 0.020 to 0.052mm
• Rocker shaft to support pedestal clearance 0.02 to 0.05mm
• Hydraulic tappet diameter 11.94 to 11.99mm
• Rocker arm to hydraulic tappet clearance 0.010 to 0.083mm

Camshaft

• Camshaft journal diameter
• No1.journal 30.975 to 31.000mm
• No 2.journal 43.348 to 43.373mm
• No.3 journal 37.975 to 38.000mm

Camshaft journal to bearing clearance

• No1.journal 0.026 to 0.071mm
• No 2.journal 0.031 to 0.076mm
• No.3 journal 0.025 to 0.075mm

Cylinder block

• Bore diameter 65.000 to 65.050mm
• Undersizes: increments of 0.010mm
• Cam follower diameter 13.982 to 14.000mm
• Cam follower to bore clearance 0.010 to 0.046mm

Pistons and piston rings

• Piston diameter
• Grade A 64.95 to 64.96mm
• Grade B 64.97 to 64.98mm
• Grade C 64.99 to 65mm

• Piston to bore clearance
• Up to engine no. 8600000 0.011 to 0.039mm
• From engine no. 8600000 0.05 to 0.07mm
• Maximum difference in piston weight +/- 5.0g
• Gudgeon pin diameter 19.974 to 19.978mm
• Gudgeon pin to piston clearance 0.008 to 0.017mm
• Piston ring to ring wall clearance 0.008 to 0.017mm
• Top compression ring 0.045 to 0.077mm
• 2nd compression ring 0.045 to 0.080mm
• Oil control ring 0.020 to 0.052mm
• Piston ring end gap
• Top compression ring 0.025 to 0.045mm
• 2nd compression ring 0.02 to 0.04mm
• Oil control ring 0.020 to 0.045mm

Connecting rods

• Gudgeon pin to small end clearance 0.014 to 0.038mm(interference fit)

Crankshaft

• Main bearing journal diameters
• Grade 1 50.795 to 50.805mm
• Grade 2 50.785 to 50.795mm
• Crankpin journal diameters 39.985 to 40.005mm
• Main bearing running clearance 0.026 to 0.061mm
• Big end bearing clearance 0.026 to 0.074mm
• Crankshaft endfloat 0.06 to 0.26mm

Torque wrench settings

• Big end bolts/nuts 41nm/30lb/ft
• Crankshaft rear oil seal housing bolts 10nm/7lb/ft
• Main bearing cap bolts 69nm/51lb/ft

OHC engine specs and torques

• Engine code 176.B2.000
• Capacity 1108cc
• Nominal bore 70.0mm
• Stroke 72.0mm
• Compression ratio 9:6:1
• Max power output 40KW@5500 RPM
• Max torque 86NM @3250RPM
• Firing order 1-3-4-2
• No1 cylinder located at timing belt end of engine

Valve clearance

• inlet 0.40 +/-0.05mm
• Exhaust 0.50 +/- 0.05mm

Lubrication system

• Oil pump is bi rotor driven from front of crankshaft
• Outer rotor to housing clearance 0.080 to 0.186mm
• Axial clearance 0.025 to 0.056mm

Torque wrench settings

• Camshaft caps:
• M8 x 1.25 20nm/15lb/ft
• M8 10nm/7lb/ft
• Camshaft cover 8nm/6lb/ft
• Camshaft sprocket 70nm/52lb/ft
• Crankshaft pulley bolt 100nm/74lb/ft
• Cylinder head
• Stage 1 30nm/22lb/ft
• Stage 2 angle tighten 90o
• Stage 3 angle tighten another 90o
• Engine mounting bolt
• M10x1.25 56nm/44lb/ft
• M8 25nm/18lb/ft
• Engine mounting nut (M10x1.25) 59nm/44lb/ft
• Flywheel 44nm/32lb/ft
• Sump 10nm/7lb/ft
• Timing belt tensioner 28nm/21lb/ft

Cylinder head

• Camshaft bearing diameters
• No.1. 24.045 to 27.070mm
• No.2. 23.545 to 23.570mm
• No.3. 24.045 to 24.070mm
• Valve seat angle 45o 30’ +/-5’
• Valve guide to bore in cylinder head
• Inlet & exhaust 0.033 to 0.080mm (interference fit)
• Valve follower (tappet) running clearance in head 0.005 to 0.050mm

Valves

• Valve stem diameter 6.982 to 7.000mm
• Valve face angle 45o 30’ +/- 5’
• Valve face width 2.0mm
• Valve stem to guide clearance 0.022 to 0.058mm
• Valve follower (tappet) shim sizes 3.2 to 4.7mm in increments of 0.05mm

Camshaft

• Camshaft bearing running clearance 0.03 to 0.07mm
• Camshaft endfloat 0.07 to 0.25mm

Cylinder block

• Bore diameter 70.000 to 70.030mm
• Undersizes increments of 0.010mm

Pistons and piston rings

• Piston diameter
• Grade A 69.96 to 69.97
• Grade B 69.97 to 69.98
• Grade C 69.98 to 69.99

• Piston to bore clearance 0.03 to 0.05mm
• Maximum difference in piston weight +/- 5.0g
• Gudgeon pin diameter 17.970 to 17.974mm
• Gudgeon pin to piston clearance 0.008 to 0.016mm
• Piston ring to ring wall clearance
• Top compression ring 0.04 to 0.08mm
• 2nd compression ring 0.02 to 0.055mm
• Oil control ring 0.2 to 0.45mm
• Piston ring end gap
• Top compression ring 0.25 to 0.45mm
• 2nd compression ring 0.25 to 0.45mm
• Oil control ring 0.2 to 0.45mm

Connecting rods

• Gudgeon pin to small end clearance 0.014 to 0.035mm(interference fit)

Crankshaft

• Main bearing journal diameters
• Grade 1 43.994 to 44.000mm
• Grade 2 43.998 to 43.994mm
• Grade 3 43.982 to 43.998mm
• Crankpin journal diameters 37.990 to 38.008mm
• Main bearing running clearance 0.025 to 0.047mm
• Big end bearing running clearance 0.024 to 0.060mm
• Crankshaft endfloat 0.055 to 0.265mm

Torque wrench settings

• Big end bolts/nuts 41nm/30lb/ft
• Main bearing cap:
• Stage 1 40nm/30lb/ft
• Stage 2 angle tighten to 90o

Cooling system

• Expansion tank pressure release cap opening pressure 0.98 BAR

Thermostat

• Starts to open 85 to 89oC
• Fully open 96 to 100oC

Electric cooling fan

• Cut in temp 90 to 94oC
• Cut out temp 85 to 89oC

Torque wrench settings

• Coolant pump
• Securing bolts (OHC) 8nm/6lb/ft
• Securing nuts(OHC) 10nm/7lb/ft
• Rear cover bolts(OHV) 7nm/5lb/ft

Fuel & exhaust system

• System type (OHV & OHC) weber marelli single point injection/ignition system

• Fuel system

• Fuel pump type: electric immersed in tank
• Delivery rate: 110 litres/hour minimum
• Regulated fuel pressure
• OHV 1.1 +/- 0.2 BAR
• OHC 1.0 +/- 0.2 BAR
• Pressure relief valve opens @ 2.6 BAR
• Coolant temp resistance (approx)
• @ 0oC 10Kohms
• @ 20oC 5Kohms
• @60oC 10Kohms
• Crankshaft TDC sensor resistance @ 20oC 575 to 720 ohms
• TDC sensor to reluctor wheel clearance 0.5 to 1.5mm
• Injector duration @ idle 1.5ms
• Lambda sensor heater resistance @ 20oC 2.5 to 4.5 ohms

• Min 95 RON unleaded fuel

Torque wrench settings

• Coolant temp sensor 2.5nm/1.8lb/ft
• Exhaust downpipe bracket (OHC) 24nm/18lb/ft
• Exhaust downpipe to manifold 18nm/13lb/ft
• Exhaust manifold 18nm/13lb/ft
• Exhaust system clamp bolts/nuts 24nm/18lb/ft
• Fuel filter collar nut 5nm/4lb/ft
• Fuel tank 28nm/21lb/ft
• Idle control steeper motor 4nm/3lb/ft
• Inlet manifold(OHC) 27nm/20lb/ft
• Lambda sensor 50nm/37lb/ft
• Throttle body to manifold 7nm/5lb/ft
• Throttle potentiometer 2.5nm/1.8lb/ft

Starting & charging systems

• 12volt negative earth system

• Starter motor magneti marelli (pre engaged)
• Output 0.8KW
• Solenoid pull in coil resistance 0.3 ohms

• Solenoid hold in coil resistance 1.2 to 1.3 ohms

Battery

• Capacity 40 A-hr
• Charge condition
• Poor 12.5V
• Normal 12.6V
• Good 12.7V

Maximum current

• OHV 200A
• OHC 150A

Alternator

• Type magneti marelli
• Maximum current
• OHC 65A
• OHV 55A
• Cut in speed
• OHC 1050 to 1150 RPM
• OHV 950 to 1050 RPM
• Field winding resistence
• OHC 2.6 to 2.8 ohms
• OHV 3.0 to 3.2 ohms

Torque wrench settings

• Alternator mounting bolts 49nm/36lb/ft
• Battery terminal clamp bolts 4nm/3lb/ft
• Wheel bolts 86nm/63lb/ft
• Starter mounting bolts 45nm/33lb/ft

Ignition system

• System type: weber-marelli static(distributorless) “wasted” spark system controlled by ECU
• Firing order 1-3-4-2
• No1 @ timing belt end
• Ignition timing
• OHC 8o +/- 3o @ 900RPM
• OHV 11o +/- 3o @ 850RPM
• Ignition coil winding resistance @ 20oC
• Primary 0.5 to 0.6 ohms
• Secondary 6.6 to 8.1 ohms

Torque wrench settings

• Spark plugs 27nm/20lb/ft

Clutch

• Single dry plate with diaphragm spring.cable operated
  
• Friction plate diameter
• OHV 170.0mm
• OHC 181.5mm

torque wrench settings

• Pressure plate retaining bolts 10nm/7lb/ft

Release fork securing bolt 25nm/18lb/ft

Manual transmission

• Transverse mounted front wheel drive layout with integral transaxle differential/final drive.

• Designation:
• OHV C.501.5.10
• OHC C.514.5.10

Driveshafts

Solid steel shafts with inner & outer constant velocity joints(CV)
Both outer joints are of the ball and cage types.
The inners are tripod types

torque wrench settings

• Front hub nut 240nm/177lb/ft
• Lower arm balljoint nut 49nm/36lb/ft
• Track rod end and ball joint to hub carrier nut 34nm/25lb/ft

Braking system

Front brakes

• Disc diameter 240.0mm
• Disc thickness
• New 10.8 to 11.1mm
• Min thickness after refinishing 9.55mm
• Minimum wear limit 9.2mm
• Maximum disc runout 0.15mm
• Brake pad minimum thickness 1.5mm

Rear brakes

• Drum internal diameter
• New 185.24 to 185.53mm
• Max diameter after refinishing 186.33mm
• Minimum (wear limit) 186.83mm
• Brake shoe friction material min thickness 1.5mm

Torque wrench settings

• Brake disc securing bolt 12nm/9lb/ft
• Brake hose to front caliper union nut 15nm/11lb/ft
• Brake pipe union nuts:
• M10 11nm/8lb/ft
• M12 18nm/13lb/ft
• Front calliper mounting bracket bolts 53nm/39lb/ft
• Handbrake lever securing nuts 15nm/11lb/ft
• Master cylinder securing nuts 20nm/15lb/ft
• Rear brake back plate securing nuts 20nm/15lb/ft
• Rear brake drum securing bolt 12nm/8lb/ft
• Rear brake pressure regulating valve bolt/nut 24nm/18lb/ft
• Rear wheel cylinder securing bolts 10nm/7lb/ft
• Vacuum servo mounting bolts 25nm/18lb/ft

Suspension & steering

Wheel alignment and steering angles
(Measured with correct tyre pressures and 5 litres of fuel)

• Front wheel castor:
• Non Sporting 1o 40’ +/- 30’
• Sporting 1o 36’ +/- 30’

• Front wheel camber:
• Non Sporting 0o 30’+/- 30’
• Sporting 0o 5’ +/- 30’

• Front wheel toe setting 0 +/- 1.0mm toe in

• Rear wheel camber:
• Non sporting 0o 30’ +/- 30’
• Sporting 0o 1’ +/- 30’

• Rear wheel toe setting:
• Non sporting 0 +/- 3mm toe in
• Sporting 1.0 +/- 3mm toe out

Front suspension
torque wrench settings

• Front hub nut 240nm/177lb/ft
• Lower arm balljoint nut 49nm/36lb/ft
• Lower arm front mounting nut 88nm/65lb/ft
• Lower arm rear mounting bolts 88nm/65lb/ft
• Suspension strut piston rod nut 88nm/65lb/ft
• Suspension strut to body nuts 25nm/18lb/ft
• Suspension strut to hub carrier nuts 108nm/78lb/ft

Rear suspension
torque wrench settings

• Rear hub nut 216nm/159lb/ft
• Rear suspension crossmember mounting bolts 88nm/65lb/ft
• Shock absorber securing bolts 49nm/36lb/ft
• Trailing arm pivot nuts 88nm/65lb/ft

Steering
torque wrench settings

• Lower steering column securing bolts 25nm/18lb/ft
• Steering column/intermediate shaft pinch bolt nut 20nm/15lb/ft
• Steering gear securing bolts 49nm/36lb/ft
• Steering wheel nut 50nm/37lb/ft
• Track rod end balljoint to hub carrier nut 34nm/25lb/ft