2004 Hyundai Brio Hatchback engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system


Intake manifold	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
Sealing rings must be replaced.

expand_moreAuxiliary assemblies


Alternator	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m

expand_moreCarburetion

expand_moreExhaust gas return valve


1.5 CRDi with diesel straight-3 1.5 L 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM engine (2002.4–2005.11)	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreExhaust recirculation pipe


1.5 CRDi with diesel straight-3 1.5 L 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM engine (2002.4–2005.11)	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreFuel-distributing pipe


1.5 CRDi with diesel straight-3 1.5 L 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM engine (2002.4–2005.11)	18.44–22.13 lbf⋅ft18.44–22.13 lbf⋅ft25–30 N⋅m

expand_moreHigh-pressure pump


1.5 CRDi with diesel straight-3 1.5 L 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM engine (2002.4–2005.11)	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreInjection nozzle (injector)


1.5 CRDi with diesel straight-3 1.5 L 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM engine (2002.4–2005.11)	18.44–22.13 lbf⋅ft18.44–22.13 lbf⋅ft25–30 N⋅m

expand_moreCooling system


Coolant pump	8.85–11.06 lbf⋅ft8.85–11.06 lbf⋅ft12–15 N⋅m
Coolant pump pulley	5.9–7.38 lbf⋅ft5.9–7.38 lbf⋅ft8–10 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Hyundai diesel straight-3 1.5 Liters D3EA engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Hyundai gasoline straight-4 1.6 Liters G4ED-G engines	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCylinder head screws

expand_moreAll Hyundai diesel straight-3 1.5 Liters D3EA engines

Figure 1. Cylinder head, Cylinder head screws, Hyundai diesel straight-3 1.5 Liters D3EA.


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Screws must be replaced. See figure 1.
Second stage	120°120°120°
Third stage	90°90°90°

expand_moreAll Hyundai gasoline straight-4 1.5 Liters G4EC-G engines

Figure 2. Cylinder head, Cylinder head screws, Hyundai gasoline straight-4 1.5 Liters G4EC-G.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws must be replaced. See figure 2.
Second stage	60°60°60°
Third stage	60°60°60°

expand_moreAll Hyundai gasoline straight-4 1.6 Liters G4ED-G engines


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Screws must be replaced.
Second stage	90°90°90°
Third stage	Loosen screw(s).
Fourth stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Fifth stage	90°90°90°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws must be replaced. See figure 2.
Second stage	60°60°60°
Third stage	60°60°60°


Rocker bridge	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Valve cover	5.9–7.38 lbf⋅ft5.9–7.38 lbf⋅ft8–10 N⋅m
Valve cover locking screws	3.69–5.9 lbf⋅ft3.69–5.9 lbf⋅ft5–8 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Hyundai diesel straight-3 1.5 Liters D3EA engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Screws must be replaced.
Second stage	90°90°90°


All other modifications	23.6–25.81 lbf⋅ft23.6–25.81 lbf⋅ft32–35 N⋅m
Screws must be replaced.


Crankcase ventilation	5.9–8.85 lbf⋅ft5.9–8.85 lbf⋅ft8–12 N⋅m

expand_moreCrankshaft central screws


All Hyundai diesel straight-3 1.5 Liters D3EA engines	136.45–143.82 lbf⋅ft136.45–143.82 lbf⋅ft185–195 N⋅m
Screws must be replaced.
All other modifications	103.26–110.63 lbf⋅ft103.26–110.63 lbf⋅ft140–150 N⋅m
Screws must be replaced.

expand_moreCrankshaft pulley


All Hyundai diesel straight-3 1.5 Liters D3EA engines	22.13–25.08 lbf⋅ft22.13–25.08 lbf⋅ft30–34 N⋅m
All other modifications	29.5–33.19 lbf⋅ft29.5–33.19 lbf⋅ft40–45 N⋅m

expand_moreFlywheel


All Hyundai diesel straight-3 1.5 Liters D3EA engines	51.63–59 lbf⋅ft51.63–59 lbf⋅ft70–80 N⋅m
Tighten the new screws evenly in several steps.
All other modifications	103.26–110.63 lbf⋅ft103.26–110.63 lbf⋅ft140–150 N⋅m

expand_moreMain bearing

expand_moreAll Hyundai diesel straight-3 1.5 Liters D3EA engines


Screws with thread length 12 mm	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreScrews with thread length 15 mm


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Second stage	120°120°120°


All other modifications	40.57–44.25 lbf⋅ft40.57–44.25 lbf⋅ft55–60 N⋅m
Screws must be replaced.

expand_moreEngine control

expand_moreCamshaft timing gear


All Hyundai diesel straight-3 1.5 Liters D3EA engines	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m
All other modifications	59–73.76 lbf⋅ft59–73.76 lbf⋅ft80–100 N⋅m


Drive belt tensioner device	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Toothed belt guard	5.9–7.38 lbf⋅ft5.9–7.38 lbf⋅ft8–10 N⋅m

expand_moreToothed belt tensioning roller


All Hyundai diesel straight-3 1.5 Liters D3EA engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Hyundai gasoline straight-4 1.6 Liters G4ED-G engines	33.19–40.57 lbf⋅ft33.19–40.57 lbf⋅ft45–55 N⋅m

expand_moreToothed belt tightener


Hyundai gasoline straight-4 1.6 Liters G4ED-G 103 HP	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Hyundai gasoline straight-4 1.3 Liters G4EA 74 HP at 5400 RPM, 114 N⋅m at 3000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Hyundai diesel straight-3 1.5 Liters D3EA 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM	36.88–40.57 lbf⋅ft36.88–40.57 lbf⋅ft50–55 N⋅m

expand_moreEngine lubrication


Oil drain plug	25.81–33.19 lbf⋅ft25.81–33.19 lbf⋅ft35–45 N⋅m
Sealing rings must be replaced.

expand_moreOil filter housing


Hyundai gasoline straight-4 1.3 Liters G4EA 74 HP at 5400 RPM, 114 N⋅m at 3000 RPM	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Hyundai diesel straight-3 1.5 Liters D3EA 80 HP at 4000 RPM, 187 N⋅m at 2000 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Hyundai gasoline straight-4 1.3 Liters G4EA 82 HP	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Hyundai gasoline straight-4 1.3 Liters G4EH 83 HP	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	8.85–11.8 lbf⋅ft8.85–11.8 lbf⋅ft12–16 N⋅m
Lubricate the sealing ring.


Oil pressure sensor	11.06–18.44 lbf⋅ft11.06–18.44 lbf⋅ft15–25 N⋅m

expand_moreOil pump


All Hyundai diesel straight-3 1.5 Liters D3EA engines	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
All other modifications	8.85–11.06 lbf⋅ft8.85–11.06 lbf⋅ft12–15 N⋅m


Oil sump	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Sealing rings must be replaced.

expand_moreEngine management


Camshaft sensor	2.95–4.43 lbf⋅ft2.95–4.43 lbf⋅ft4–6 N⋅m
Crankshaft sensor	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Glow plugs	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
Knock sensor	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Lambda sensor	36.88–44.25 lbf⋅ft36.88–44.25 lbf⋅ft50–60 N⋅m

expand_moreEngine mounting


Engine bracket	22.13–29.5 lbf⋅ft22.13–29.5 lbf⋅ft30–40 N⋅m

expand_moreEngine mounting

expand_moreAll Hyundai diesel straight-3 1.5 Liters D3EA engines


Nuts on engine bracket	44.25–59 lbf⋅ft44.25–59 lbf⋅ft60–80 N⋅m
Screws on chassis	66.38–81.13 lbf⋅ft66.38–81.13 lbf⋅ft90–110 N⋅m
Screws on engine bracket	44.25–59 lbf⋅ft44.25–59 lbf⋅ft60–80 N⋅m

expand_moreAll Hyundai gasoline straight-4 1.6 Liters G4ED-G engines


Nuts on engine bracket	36.88–47.94 lbf⋅ft36.88–47.94 lbf⋅ft50–65 N⋅m
Screws on chassis	66.38–81.13 lbf⋅ft66.38–81.13 lbf⋅ft90–110 N⋅m
Screws on engine bracket	36.88–47.94 lbf⋅ft36.88–47.94 lbf⋅ft50–65 N⋅m

expand_moreAll other modifications


On chassis	66.38–81.13 lbf⋅ft66.38–81.13 lbf⋅ft90–110 N⋅m
On engine bracket	36.88–47.94 lbf⋅ft36.88–47.94 lbf⋅ft50–65 N⋅m

expand_moreExhaust system

expand_moreExhaust manifold


All Hyundai diesel straight-3 1.5 Liters D3EA engines	18.44–29.5 lbf⋅ft18.44–29.5 lbf⋅ft25–40 N⋅m
All Hyundai gasoline straight-4 1.6 Liters G4ED-G engines	33.19–40.57 lbf⋅ft33.19–40.57 lbf⋅ft45–55 N⋅m
All other modifications	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreExhaust manifold heat shield(s)


1.6 with gasoline straight-4 1.6 L 103 HP engine (2002.12–2005.11)	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreFuel supply


Fuel filter housing	7.38–10.33 lbf⋅ft7.38–10.33 lbf⋅ft10–14 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


Hyundai gasoline straight-4 1.3 Liters G4EA 74 HP at 5400 RPM, 114 N⋅m at 3000 RPM	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
Hyundai gasoline straight-4 1.3 Liters G4EA 82 HP	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
Hyundai gasoline straight-4 1.3 Liters G4EH 83 HP	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
All other modifications	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreStart system


Starter	18.44–25.81 lbf⋅ft18.44–25.81 lbf⋅ft25–35 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Hyundai Brio Hatchback user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Hyundai warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Hyundai Brio Hatchback service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2004 Hyundai Brio Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

2004 Hyundai Brio Hatchback Second generation facelift Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Hyundai Brio Hatchback Second generation facelift model years

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