1994 Mitsubishi Expo

1994 ENGINES 1.8L 4-Cylinder

1994 ENGINES

1.8L 4-Cylinder

ENGINE IDENTIFICATION

NOTE: For engine repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES article in the GENERAL INFORMATION.

Vehicle Identification Number (VIN) is stamped on a metal plate located at upper left corner of instrument
panel, near windshield. The eighth character of VIN identifies engine, and tenth character (R) identifies model
year (1994).

Engine code and serial number are stamped on right side of cylinder block, near front. For specific location,
refer to the ENGINE/VIN ID article in the ENGINE PERFORMANCE section.

ENGINE IDENTIFICATION CODES

Engine Code VIN Code
4G93 C

ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT

1. Adjust valves when engine temperature is 176-203°F (80-95°C). Remove spark plugs and valve cover.
Rotate crankshaft counterclockwise until "T" mark is lined up with notch on crankshaft pulley.

CAUTION: Always rotate engine in direction of normal rotation

(counterclockwise as viewed from front of engine).

2. Ensure valve stem-to-rocker arm clearance is present at cylinder No. 1. If clearance is not present, rotate
crankshaft another 360 degrees. Ensure "T" mark on timing indicator is lined up with notch on crankshaft
pulley. Adjust clearance on both valves for cylinder No. 1 and exhaust valve for cylinder No. 3. Adjust
cylinder No. 2 intake valve. Refer to VALVE CLEARANCE SPECIFICATIONS table. Refer to Fig.
Fig. 1.
3. Rotate crankshaft 360 degrees counterclockwise so piston No. 4 is at TDC of compression stroke. Ensure
"T" mark on timing indicator is lined up with notch on crankshaft pulley. Adjust clearance on both valves
for cylinder No. 4. Adjust cylinder No. 3 intake valve and cylinder No. 2 exhaust valve. See Fig. 1. Install
new valve cover gasket. Install valve cover.

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Fig. 1: Valve Clearance Adjusting Sequence

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

VALVE CLEARANCE SPECIFICATIONS

Application In. (mm)
Exhaust .012 (.30)
Intake .008 (.20)

REMOVAL & INSTALLATION

GENERAL PRECAUTIONS

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.

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 1994 Mitsubishi Expo
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NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.

FUEL PRESSURE RELEASE

Disconnect fuel pump connector near fuel tank. Start engine, and allow it to idle until it stalls. Turn ignition off.
Reconnect fuel pump connector. Disconnect negative battery cable before disconnecting fuel lines.

ENGINE

CAUTION: To prevent fire hazard, release residual pressure in fuel system before
disconnecting fuel lines.

Removal

1) Release residual fuel pressure from fuel system. Refer to FUEL PRESSURE RELEASE under REMOVAL
& INSTALLATION in this article. Remove hood and air cleaner assembly.

2) Remove all necessary electrical connectors, vacuum hoses, fuel hoses, coolant hoses and cables. Remove
accelerator cable. Drain cooling system. Drain engine oil and transaxle oil. Remove transaxle. For M/T models,
see appropriate CLUTCH article in CLUTCHES section under the POWERTRAIN category. For A/T models,
refer to the appropriate TRANSMISSION REMOVAL & INSTALLATION - A/T article in the
AUTOMATIC TRANS SERVICING section.

3) Remove radiator. Leaving hoses connected, remove power steering pump and A/C compressor, and support
aside using wire. Remove all drive belts. Remove exhaust manifold heat shield. Disconnect exhaust pipe from
exhaust manifold. Disconnect front and rear lower engine mounts.

4) Support engine using hoist. Remove engine mount brackets. Raise engine slightly. Ensure all cables, hoses
and electrical harnesses are disconnected from engine. Lift engine assembly upward from vehicle to remove
from engine compartment.

Installation

To install, reverse removal procedure. Ensure all wiring and hoses are cleared when lowering engine into engine
compartment. With weight of engine on insulators, tighten mounting bolts and nuts to specification. See
TORQUE SPECIFICATIONS. Replace all fluids. Adjust all cables and linkages.

INTAKE MANIFOLD

CAUTION: To prevent fire hazard, release residual pressure in fuel system before
disconnecting fuel lines.

Removal

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 1994 Mitsubishi Expo
1994 ENGINES 1.8L 4-Cylinder

1. Release residual fuel pressure from fuel system. Refer to FUEL PRESSURE RELEASE under
REMOVAL & INSTALLATION.
2. Disconnect negative battery cable. Drain cooling system. Disconnect air intake hose or turbo supply hose
from throttle body inlet. Remove air cleaner assembly (if necessary).

CAUTION: DO NOT allow fuel injectors to fall out when removing fuel delivery
pipe.

3. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses and cables from
intake manifold, injectors and throttle body. On all models, remove delivery pipe with fuel injectors and
pressure regulator attached. See Fig. 2.
4. Remove support brace from below intake manifold. Remove intake manifold-to-cylinder head bolts.
Remove intake manifold and gasket. If necessary, remove remaining components from intake manifold.

Installation

To install, reverse removal procedure. Use new gaskets, fuel injector insulators and "O" rings. Adjust all control
cables. Fill cooling system.

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Fig. 2: View Of Intake Manifold & Related Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

EXHAUST MANIFOLD

Removal

Disconnect exhaust pipe from manifold. Remove exhaust manifold outer heat shield and O2 sensor from
manifold. Remove manifold bolts, manifold, gasket and manifold inner heat shield.

Installation

To install, reverse removal procedure. Use new gaskets and manifold nuts.

TURBOCHARGER

NOTE: For turbocharger removal and installation procedures, see EXHAUST

MANIFOLD under REMOVAL & INSTALLATION.

CYLINDER HEAD

CAUTION: Release residual pressure in fuel system before disconnecting fuel lines.

Removal

1. Release residual fuel pressure from fuel system. Refer to FUEL PRESSURE RELEASE under
REMOVAL & INSTALLATION. Drain cooling system.
2. Disconnect all necessary electrical connectors, vacuum hoses, coolant hoses, fuel hoses and cables.
Support timing belt end of engine from below. Remove engine mount at timing belt end of engine.

CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt
end of engine).

3. Remove rocker cover. Remove timing belt upper front cover. Rotate crankshaft clockwise (as viewed
from timing belt end of engine) until timing mark on camshaft sprocket aligns with timing mark on upper
rear cover. See Fig. 7.
4. Wire timing belt and sprocket together to maintain correct position. Remove camshaft sprocket with
timing belt attached, and allow it to rest on lower front cover. Remove timing belt upper rear cover. On
all models, disconnect exhaust pipe from exhaust manifold.
5. Remove intake manifold support bracket. Using Cylinder Head Bolt Wrench (MD998051), loosen
cylinder head bolts (in 2-3 steps) in proper sequence. See Fig. 3. Remove cylinder head and gasket.

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Fig. 3: Cylinder Head Bolt Removal & Installation Sequence

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Inspection

Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds specification.
See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Installation

1. Install cylinder head using new gasket. Ensure identification mark at timing belt end of gasket faces
upward. DO NOT apply sealant to head gasket. Install and tighten cylinder head bolts (in 5 steps) to
specification in proper sequence. See Fig. 3. See TORQUE SPECIFICATIONS.
2. To complete installation, reverse removal procedure. Apply sealant to contact surfaces of semi-circular
packing. Apply gasoline to "O" ring on fuel line before installing fuel line in fuel delivery pipe. Adjust all
control cables. Fill cooling system.

FRONT COVER OIL SEAL

NOTE: Front cover refers to cover at front of cylinder block. Cover contains oil pump
and front cover oil seal (crankshaft front seal). Manufacturer lists oil seal
removal procedure with front cover removed from engine. See OIL PUMP &
FRONT COVER under ENGINE OILING.

TIMING BELT

CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise

(as viewed from timing belt end of engine).

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Fig. 4: View Of Timing Belts & Related Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: Ensure timing marks are aligned. Mark direction of rotation of all timing belts.

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 1994 Mitsubishi Expo
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Fig. 5: Installing Timing Belt "B" Tensioner (Typical)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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Fig. 6: Checking Timing Belt "A" Tension (Typical)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Removal

1. Remove condenser tank. Remove A/C and power steering hose mounting bracket from upper engine
mount at timing belt cover. Remove all drive belts. Using End Yoke Holder (MB990767) and Crankshaft
Pulley Holder (MD998718), remove crankshaft pulley bolt and pulley.

CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing

belt end of engine).

2. Remove upper and lower timing belt covers. Remove flange. Rotate crankshaft clockwise (as viewed
from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke, and timing mark on
camshaft sprocket and crankshaft sprocket align with timing mark on engine. See Fig. 7.
3. If timing belt is to be reused, mark direction of rotation before removing. Loosen timing belt tensioner
bolt. Using a screwdriver, move tensioner away from timing belt. Tighten bolt to secure tensioner.
Remove timing belt.

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 1994 Mitsubishi Expo
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Fig. 7: Aligning Timing Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Inspection

Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check belt
tensioner for grease leakage or roughness in tensioner rotation. Replace components if damaged.

Installation

1. Install timing belt tensioner, leaving bolt loose. Using a screwdriver, push tensioner toward engine mount.
Tighten timing belt tensioner bolt.
2. Align camshaft sprocket and crankshaft sprocket timing marks with timing marks on engine. Install

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timing belt. Loosen timing belt tensioner to apply spring pressure to timing belt. Ensure timing marks are
still aligned.
3. Tighten timing belt tensioner bolt. Rotate camshaft in reverse direction and ensure that there is no slack in
timing belt. Rotate crankshaft 2 complete revolutions clockwise (as viewed from timing belt end of
engine) and ensure timing marks are still aligned.
4. Ensure timing belt teeth are properly seated in sprockets. Install flange. See Fig. 8. To complete
installation, reverse removal procedure. Ensure proper length bolts are installed in designated areas in
timing belt covers. See Fig. 9.

Fig. 8: Installing Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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Fig. 9: Identifying Timing Belt Cover Bolt Locations

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

ROCKER ARM & VALVE LASH ADJUSTER

CAUTION: DO NOT rotate crankshaft if timing belt has been removed. DO NOT rotate
crankshaft counterclockwise (as viewed from timing belt end of engine).

Removal

1. Remove valve cover and semi-circular packing from rear of cylinder head. Remove upper front timing
belt cover. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is
at TDC of compression stroke.

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2. Ensure timing mark on camshaft sprocket aligns with timing mark on upper cover. See Fig. 7. Mark
timing belt in alignment with timing mark on camshaft sprocket. Wire belt to sprocket. Remove camshaft
sprocket bolt.
3. Slide camshaft sprocket and belt off camshaft. Loosen rocker shaft mounting bolts uniformly, and remove
rocker shaft assembly. Remove camshaft and oil seal.

Inspection

1. Inspect rocker arms and shafts for wear and damage. Check distributor drive gear for tooth damage and
wear. Replace components as necessary.
2. Check camshaft journal diameter and lobe height. Replace camshaft if journal diameter and lobe height
are not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

Installation

1. Lubricate camshaft lobes and camshaft bearing journals. Install camshaft into cylinder head.
2. Ensure rocker arms are installed in original location. Tighten the camshaft bearing cap bolts to
specification. Refer to TORQUE SPECIFICATIONS.
3. Coat lip of camshaft oil seal with oil. Install seal into cylinder head using Seal Installer (MD998713-01).
To complete installation, reverse removal procedure.

CAMSHAFT

NOTE: For removal and installation of camshaft, see ROCKER ARM & VALVE LASH
ADJUSTER under REMOVAL & INSTALLATION.

REAR CRANKSHAFT OIL SEAL

Removal

1. Remove transaxle/transmission. For A/T vehicles, refer to the TRANSMISSION REMOVAL &
INSTALLATION - A/T article in the AUTOMATIC TRANS SERVICING section. For M/T vehicles,
see appropriate CLUTCH article in CLUTCHES section under the POWERTRAIN category.
2. Remove flywheel or drive plate. Remove rear main oil seal case and gasket from rear of cylinder block.
Remove oil separator and oil seal from seal case.

Installation

1. Coat seal lip with oil. Using Seal Installer (MD998011 for Eclipse, MD998776 for all models except
Eclipse, install seal in seal case until it bottoms.
2. Install oil separator in seal case with hole of separator at bottom of seal case (toward oil pan). Install seal
case and gasket. Install flywheel or drive plate. To complete installation, reverse removal procedure.

WATER PUMP

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CAUTION: Note length and location of bolts during removal. Different length bolts are
used and must be installed in original location.

Removal

Drain cooling system. Remove necessary coolant hoses. Remove timing belt. See TIMING BELT under
REMOVAL & INSTALLATION. Remove water pump mounting bolts. Note bolt length and location. Remove
water pump.

Installation

To install, reverse removal procedure using new gasket and "O" ring. Install "O" ring on coolant pipe, and apply
water to "O" ring. DO NOT apply grease or oil to "O" ring. Ensure bolts are installed in original location.

OIL PAN

Removal

1. Drain engine oil. On Expo 4WD, Summit Wagon 4WD and Vista Wagon 4WD, remove transfer case.
See appropriate axle shaft article in DRIVE AXLES.
2. On all models, remove oil pan bolts. Using Gasket Cutter (MD998727), cut gasket along sealing surface
of cylinder block. Remove oil pan and gasket.

Installation

To install, apply sealant to oil pan flange at timing chain case and rear seal case areas. Install oil pan and
gaskets. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.

OVERHAUL
CYLINDER HEAD

Cylinder Head

Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds specification.
See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

Inspect valve spring free length, out-of-square and installed height. Replace valve spring if not within
specification. Refer to VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Install all
valve springs with painted area toward rocker arm.

Valve Stem Oil Seals

DO NOT reuse oil seals. Install valve spring seat before installing oil seals. To provide proper positioning of oil

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 1994 Mitsubishi Expo
1994 ENGINES 1.8L 4-Cylinder

seal, install new oil seals using Valve Seal Installer (MD998774).

Valve Guides

Ensure valve stem diameter is within specification. Check valve stem clearance. Clearance should be within
specification. Refer to, under ENGINE SPECIFICATIONS, the VALVES & VALVE SPRINGS and
CYLINDER HEAD tables. If clearance exceeds service limits, replace valve guide with an oversized valve
guide.

Valves

Ensure valve stem diameter and margin are within specification. See VALVES & VALVE SPRINGS table
under ENGINE SPECIFICATIONS.

Valve Seat

See the ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL
INFORMATION section.

Valve Seat Correction Angles

See the ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL
INFORMATION section.

VALVE TRAIN

Rocker Arm Shaft Assembly

1. For reassembly reference, note location and order of assembly for all components. Remove bolts from
shafts, and separate components. Note length of springs. Intake rocker arm shaft springs are longer than
exhaust rocker arm shaft springs.
2. Inspect components for wear and damage. Install components in original location when reassembling
shaft assembly. Tighten rocker arm assembly bolts to specification. See TORQUE SPECIFICATIONS.

Lash Adjusters

Before installing lash adjuster, submerge lash adjuster in oil. Use a small wire to hold down internal check
valve. Pump plunger up and down 4 or 5 times to bleed air from lash adjuster.

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

1. Mark piston and rod assembly with corresponding cylinder number before removing. Center piston pin in
piston. Measure and record piston pin installation depth. Use Piston Pin Removal & Installation Set
(MD998780) with hydraulic press to remove piston pin.
2. Piston pin should be easily pushed into piston. If looseness or resistance is encountered, replace piston
and pin as a set. Check connecting rod for damage and excessive bend and twist. See CONNECTING

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RODS table under ENGINE SPECIFICATIONS.

3. Position piston, piston pin and rod on press. Ensure front mark on piston will face timing belt side of
engine when installed. Using piston pin removal and installation set, install piston pin into piston and rod
to depth recorded in step 1). Ensure piston pin is centered in piston.

Fitting Pistons

1. Measure piston skirt diameter at 90-degree angle to piston pin. If piston diameter is not within
specification, replace piston. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter at 3 places: near top of bore, bottom of bore and center of bore. If
cylinder bore diameter or taper is not within specification, machine cylinder bore. Refer to CYLINDER
BLOCK table under ENGINE SPECIFICATIONS.
3. If piston-to-cylinder bore clearance is not within specification, replace piston and/or machine cylinder
bore. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS. DO NOT use a ring expander to install oil ring side rails. Properly position ring
end gaps around circumference of piston before installing. See Fig. 10.

Fig. 10: Positioning Piston Ring Gaps

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Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Rod Bearings

Note position of connecting rod in relation to bearing cap before removing. Ensure bearing oil clearance and
side play are within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and
CONNECTING RODS tables under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

Check diameter of crankshaft main bearing journals and connecting rod bearing journals. Check journals for
taper and out-of-round. Check crankshaft end play. See CRANKSHAFT, MAIN & CONNECTING ROD
BEARINGS table under ENGINE SPECIFICATIONS.

Thrust Bearing

Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Check cylinder block head surface warpage. If warpage exceeds specification, machine surface. See
CYLINDER BLOCK table under ENGINE SPECIFICATIONS. DO NOT remove more than a
combined total .008" (0.20 mm) material from original surfaces of cylinder head or cylinder block.
2. Check cylinder bore wear and taper. Measure cylinder bore diameter at 3 places: near top of bore, bottom
of bore and center of bore. If cylinder bore diameter or taper is not within specification, machine cylinder
bore. See CYLINDER BLOCK table.

ENGINE OILING
ENGINE LUBRICATION SYSTEM

Oil pressure is provided by a belt-driven oil pump mounted in front cover. Pressure relief valve is not
adjustable, and is located either in front cover or oil filter bracket. See Fig. 11.

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Fig. 11: Engine Oiling System

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CRANKCASE CAPACITY SPECIFICATIONS

Application (1) Qts. (L)

1.8L 4.0 (3.8)

(1) Includes oil filter.

Oil Pressure

Oil pressure should be at least 11.4 psi (.80 kg/cm2 ) at curb idle, and oil temperature should be 167-194°F (75-
90°C).

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OIL PUMP & FRONT COVER

Removal

1. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. If necessary, remove oil filter
bracket assembly. Remove oil pick-up assembly.
2. Remove timing belt and sprockets. See TIMING BELT under REMOVAL & INSTALLATION.
Remove oil pump drive gear. Remove oil pump cover and gasket. Remove front cover from cylinder
block.
3. If front cover sticks to cylinder block, pry cover from cylinder block at screwdriver slot. Remove plug,
spring and relief plunger.

Inspection

1. Inspect components for damage. Install oil pump gears in front cover. Using feeler gauge, measure gear-
to-front cover clearance between tip of teeth on each gear and front cover.
2. Place straightedge across front cover above gears. Using feeler gauge, check gear side clearance between
straightedge and both oil pump gears. On Colt Vista, Expo & Summit Wagon, check clearance between
gear (rotor) tips.
3. Check for ridge on oil pump cover in gear operating area. Ensure relief plunger slides freely in bore.
Ensure spring free length is 1.85" (47.0 mm). Replace components if not within specification. See OIL
PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

Application Specification
Gear Side Clearance .0015-.0039" (.040-.100 mm)
Gear Tip Clearance .0024-.0071" (.060-.180 mm)
Gear-To-Front Cover Clearance
Standard .0039-.0071" (.100-.180 mm)
Limit .0138" (.351 mm)

Installation

1. If crankshaft oil seal was removed, use Seal Installer (MD998304) to install seal in front cover. Install
gears in oil pump case. Attach oil pump case cover and go to step 4).
2. Position Oil Seal Guide (MD998285) over front of crankshaft. Lubricate crankshaft oil seal and oil seal
guide with engine oil.
3. Install front cover with new gasket. Ensure bolts of appropriate length are installed. Install oil pump gears
with timing marks aligned. Lubricate gears with engine oil. Install oil pump cover gasket with rounded
side toward oil pump cover.
4. On all models, to complete installation, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.

TORQUE SPECIFICATIONS

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TORQUE SPECIFICATIONS (1.8L)

Application Ft. Lbs. (N.m)
A/C Tensioner Pulley Bolt 18 (24)
Camshaft Sprocket Bolt 66 (90)
Connecting Rod Cap Bolt (1)

Crankshaft Pulley/Dampener Bolt1 136 (185)

Cylinder Head Bolt (Cold Engine) (2)
Step 1 55 (75)
Step 2 Fully Loosen
Step 3 14.5 (20)
Step 4 1/4 turn (90
degrees)
Step 5 1/4 turn (90
degrees)
Engine Support Bracket Bolt 36-47 (49-64)
Exhaust Manifold Nut (Upper) 11-14 (15-19)
Exhaust Manifold Nut (Lower) 22 (30)
Flywheel/Drive Plate Bolt 72 (100)
Intake Manifold Bolt 14 (19)
Main Bearing Cap Bolt (3)

Oil Drain Pan Bolt 29 (40)

Oil Filter Bracket Bolt 11-16 (15-22)
Oil Pick-Up Tube Bolt 14 (19)
Oil Pump Relief Plug 33 (45)
Oil Pump Case Mounting Bolt 10 (14)
Oil Pump Case Cover Mounting Bolt 7 (10)
Oil Pressure Switch 7 (10)
Oil Seal Case Mounting Bolt 8 (11)
Power Steering Pump Bolts 33 (45)
Oxygen Sensor 33 (45)
Rocker Arm Assembly Bolts 23 (32)
Thermostat Housing Bolts 14 (19)
Throttle Body Bolt 14 (19)
Timing Belt Pulley Tensioner Bolt 18 (24)
Timing Belt Pulley Tensioner Spring Bolt 33 (45)
Water Pump Bolt
Except 8 x 65-mm 10 (14)
8 x 65-mm 15-19 (20-26)
INCH Lbs. (N.m)
Bell Housing Cover Bolts To Block 80 (9)
Bell Housing Cover Bolt To Trans 80 (9)

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Fuel Rail Bolt 108 (12)

Oil Pan Bolt/Nut 61 (7)
Timing Belt Cover Bolt 88 (10)
Valve Cover Bolt 34 (4)
(1) First tighten to 15 ft. lbs. (20 N.m), then tighten nut an additional 1/4 turn.

(2) Tighten bolts to specification in sequence. See Fig. 3.

(3) First tighten to 18 ft. lbs. (25 N.m), then tighten nut an additional 1/4 turn.

ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS
Application Specification
Displacement 111 Cu. In. (1.8L)
Bore 3.19" (81.0 mm)
Stroke 3.50" (89.0 mm)
Compression Ratio 8.5:1
Fuel System PFI
Horsepower @ RPM (1)

Torque Ft. Lbs. @ RPM (1)

(1) Information is not available from manufacturer.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft End Play
Standard .0020-.0070 (.051-.178)
Wear Limit .016 (.41)
Main Bearings
Journal Diameter 2.244 (57.00)
Journal Out-Of-Round .0006 (.015)
Journal Taper .0002 (.005)
Oil Clearance
Standard .0008-.0016 (.020-.040)
Wear Limit .004 (.10)
Connecting Rod Bearings
Journal Diameter 1.771 (45.00)
Journal Out-Of-Round .0006 (.015)

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 1994 Mitsubishi Expo
1994 ENGINES 1.8L 4-Cylinder

Journal Taper .0002 (.005)

Oil Clearance
Standard .0008-.0020 (.020-.050)
Wear Limit .004 (.10)

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS
Application In. (mm)
Maximum Bend .0020 Per 3.937 (.051 Per 100.00)
Maximum Twist .0039 Per 3.937 (.01 Per 100.00)
Side Play
Standard .0039-.0098 (.010-.250)
Wear Limit .016 (.41)

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

Application In. (mm)
Pistons
Clearance .0008-.0016 (.020-.040)
Diameter 3.1882-3.1886 (80.980-80.990)
Pin-to-Rod Fit (1)

Rings
No. 1
End Gap
Standard .0098-.0157 (.250-.400)
Wear Limit .031 (.79)
Side Clearance
Standard .0012-.0028 (.030-.070)
Wear Limit .004 (.10)
No. 2
End Gap
Standard .0157-.0217 (.400-.550)
Wear Limit .031 (.79)
Side Clearance
Standard .0008-.0024 (.020-.060)
Wear Limit .004 (.10)
Oil Ring Side Rail .0079-.0236 (.200-.600)
(1) Press fit with load of 1100-3300 lbs. (499-1497 kg).

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 1994 Mitsubishi Expo
1994 ENGINES 1.8L 4-Cylinder

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK
Application In. (mm)
Cylinder Bore
Standard Diameter 3.1894-3.1898 (81.010-
81.020)
Maximum Taper .0004 (.010)
Maximum Out-Of-Round .0004 (.010)
Deck Height (2)

Maximum Deck Warpage (1) .0039 (.099)

(1) Combined maximum total grind limit of cylinder head and cylinder block is .008" (.20 mm).

(2) Information is not available from manufacturer.

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

Application Specification
Intake Valves
Face Angle 45-45.5°
Minimum Margin .019" (.48 mm)
Stem Diameter .235" (5.97 mm)
Exhaust Valves
Face Angle 45-45.5°
Minimum Margin .039" (1.00 mm)
Stem Diameter .234" (5.95 mm)
Valve Springs
Free Length 1.965-2.004" (48.21-49.20 mm)
Installed Height (1)

Out-Of-Square
Standard Less Than 2°
Wear Limit 4°
(1) Information is not available from manufacturer.

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD
Application Specification
Cylinder Head Height 4.720" (119.90 mm)
Maximum Warpage (1) .0012" (.030 mm)

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 1994 Mitsubishi Expo
1994 ENGINES 1.8L 4-Cylinder

Valve Seats
Intake Valve
Seat Angle 43.5-44.0°
Seat Width .0354-.0512" (.899-1.300 mm)
Exhaust Valve
Seat Angle 43.5-44.0°
Seat Width .0354-.0512" (.899-1.300 mm)
Valve Guides
Intake Valve
Valve Stem-To-Guide Oil Clearance
Standard .0008-.0020" (.020-.050 mm)
Wear Limit .004" (.10 mm)
Exhaust Valve
Valve Stem-To-Guide Oil Clearance
Standard .0020-.0035" (.050-.090 mm)
Wear Limit .006" (.15 mm)
(1) Combined maximum total grind limit of cylinder head and cylinder block is .008" (.20 mm).

CAMSHAFT SPECIFICATIONS

CAMSHAFT
Application In. (mm)
End Play .004-.008 (.10-.20)
Journal Diameter 1.7689-1.7693 (44.930-44.940)
Lobe Height
Intake 1.4677-1.4876 (37.280-
37.780)
Exhaust 1.4799-1.4996 (37.590-
38.090)
Oil Clearance .0020-.0035 (.051-.089)

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