2002 Hyundai H-200 Van 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

expand_moreAuxiliary assemblies


Air-conditioning compressor	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m
Alternator	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Auxiliary drive belt tensioner	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Servo steering pump	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Vacuum pump	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreCarburetion


High-pressure pump pulley	47.94–55.32 lbf⋅ft47.94–55.32 lbf⋅ft65–75 N⋅m
Injection hoses	17.7–20.65 lbf⋅ft17.7–20.65 lbf⋅ft24–28 N⋅m
Injection lines must be replaced.
Injection nozzle (injector)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreInjection pump


At the bracket	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
On the engine block	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreCooling system


Coolant pump	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Coolant pump pulley	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Fan wheel	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreCylinder head


Camshaft bearing	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreCylinder head screws

Figure 1. Cylinder head, Cylinder head screws.


First stage	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m
Screws must be replaced. See figure 1.
Second stage	120°120°120°
Third stage	90°90°90°

expand_moreRocker bridge


2.5 D with diesel straight-4 2.5 L 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM engine (1997.10–2004.4)	25.81–29.5 lbf⋅ft25.81–29.5 lbf⋅ft35–40 N⋅m

expand_moreValve cover


Hyundai diesel straight-4 2.5 Liters D4CB 138 HP	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreEngine block

expand_moreBalance shaft gear wheel


Left nuts	36.88–44.25 lbf⋅ft36.88–44.25 lbf⋅ft50–60 N⋅m
Left screws	25.81–33.19 lbf⋅ft25.81–33.19 lbf⋅ft35–45 N⋅m
Right screws	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreConnecting rod bearing

expand_moreHyundai diesel straight-4 2.5 Liters D4CB 138 HP


First stage	43.52 lbf⋅ft43.52 lbf⋅ft59 N⋅m
Screws and nuts must be replaced.
Second stage	slacken
Third stage	23.6–26.55 lbf⋅ft23.6–26.55 lbf⋅ft32–36 N⋅m
Fourth stage	60–64°60–64°60–64°


Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	33.19–36.88 lbf⋅ft33.19–36.88 lbf⋅ft45–50 N⋅m

expand_moreCrankshaft central screws


2.4 4WD with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (1998.2–2004.4)	81.13–95.88 lbf⋅ft81.13–95.88 lbf⋅ft110–130 N⋅m
2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (1997.6–2004.4)	81.13–95.88 lbf⋅ft81.13–95.88 lbf⋅ft110–130 N⋅m
2.5 CRDi 4WD with diesel straight-4 2.5 L 138 HP engine (2002.12–2004.4)	206.52–221.27 lbf⋅ft206.52–221.27 lbf⋅ft280–300 N⋅m
2.5 CRDi with diesel straight-4 2.5 L 138 HP engine (2002.12–2004.4)	206.52–221.27 lbf⋅ft206.52–221.27 lbf⋅ft280–300 N⋅m
All other modifications	125.39–140.14 lbf⋅ft125.39–140.14 lbf⋅ft170–190 N⋅m


Crankshaft pulley	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Flywheel	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m

expand_moreMain bearing


Hyundai diesel straight-4 2.5 Liters D4CB 138 HP	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	55.32–62.69 lbf⋅ft55.32–62.69 lbf⋅ft75–85 N⋅m

expand_moreEngine control


Balance shaft toothed belt tension pulley	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreBottom part of the control unit housing


M6	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
M8	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m


Camshaft timing chain guide rail	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Camshaft timing chain tensioner	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Camshaft timing chain tensioning rail	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreCamshaft timing gear


Hyundai diesel straight-4 2.5 Liters D4CB 138 HP	70.07–88.51 lbf⋅ft70.07–88.51 lbf⋅ft95–120 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	47.94–55.32 lbf⋅ft47.94–55.32 lbf⋅ft65–75 N⋅m

expand_moreControl drive chain guide rail

expand_moreHigh-pressure pump timing chain


Top screws	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Bottom screws	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreTiming chain


Oil pump	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreControl drive chain tensioner


High-pressure pump timing chain	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreTiming chain


Oil pump	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreControl drive chain tensioning rail


High-pressure pump timing chain	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m


Drive belt tensioner device	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Toothed belt guard	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreToothed belt tensioning roller


2.4 4WD with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (1998.2–2004.4)	33.19–40.57 lbf⋅ft33.19–40.57 lbf⋅ft45–55 N⋅m
2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (1997.6–2004.4)	33.19–40.57 lbf⋅ft33.19–40.57 lbf⋅ft45–55 N⋅m
2.4 with gasoline straight-4 2.4 L 143 HP engine (2001.11–2004.4)	33.19–40.57 lbf⋅ft33.19–40.57 lbf⋅ft45–55 N⋅m
All other modifications	25.08–29.5 lbf⋅ft25.08–29.5 lbf⋅ft34–40 N⋅m

expand_moreToothed belt tightener


2.5 D with diesel straight-4 2.5 L 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM engine (1997.10–2004.4)	16.23–22.13 lbf⋅ft16.23–22.13 lbf⋅ft22–30 N⋅m

expand_moreEngine lubrication

expand_moreOil cooler


Heat-exchanger on oil filter housing	13.28–18.44 lbf⋅ft13.28–18.44 lbf⋅ft18–25 N⋅m


Oil drain plug	25.81–33.19 lbf⋅ft25.81–33.19 lbf⋅ft35–45 N⋅m

expand_moreOil filter


Filter cartridge	16.23–18.44 lbf⋅ft16.23–18.44 lbf⋅ft22–25 N⋅m

expand_moreOil filter housing


On the engine block	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m

expand_moreOil sump

expand_moreHyundai diesel straight-4 2.5 Liters D4CB 138 HP

expand_moreOil sump top part


M6	5.9–8.85 lbf⋅ft5.9–8.85 lbf⋅ft8–12 N⋅m
M8	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m


Oil sump lower part	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m


Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	4.43–5.9 lbf⋅ft4.43–5.9 lbf⋅ft6–8 N⋅m

expand_moreEngine management


Camshaft 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

expand_moreEngine mounting


Subframe	88.51–118.01 lbf⋅ft88.51–118.01 lbf⋅ft120–160 N⋅m

expand_moreExhaust system

expand_moreExhaust manifold


Hyundai diesel straight-4 2.5 Liters D4CB 138 HP	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BF 76 HP at 4000 RPM, 208 N⋅m at 1800 RPM	22.13–25.81 lbf⋅ft22.13–25.81 lbf⋅ft30–35 N⋅m

expand_moreStart system


Starter	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2002 Hyundai H-200 Van 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 H-200 Van 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 2002 Hyundai H-200 Van you're not only saving money, but also also improving your technical skills and learning something new.

2002 Hyundai H-200 Van First generation Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Hyundai H-200 Van First generation model years

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