2002 Hyundai Starex Box Van engine fastener tightening specifications

in your garage to make future searches easy.

Condition	Value

expand_moreAir intake system

expand_moreIntake manifold

expand_moreAll Hyundai gasoline straight-4 2.4 Liters G4CS engines


Nuts	22.13–29.5 lbf⋅ft22.13–29.5 lbf⋅ft30–40 N⋅m
Screws	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m


All other modifications	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreAuxiliary assemblies

expand_moreAir-conditioning compressor


Hyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m
Hyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM	18.44 lbf⋅ft18.44 lbf⋅ft25 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

expand_moreServo steering pump


Hyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Hyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM	25.81–33.19 lbf⋅ft25.81–33.19 lbf⋅ft35–45 N⋅m


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

expand_moreCarburetion

expand_moreFuel-distributing pipe


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m


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.

expand_moreInjection nozzle (injector)


Hyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	36.88–44.25 lbf⋅ft36.88–44.25 lbf⋅ft50–60 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	36.88–44.25 lbf⋅ft36.88–44.25 lbf⋅ft50–60 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

expand_moreCamshaft bearing


Hyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCylinder head screws

expand_moreHyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM

Figure 1. Cylinder head, Cylinder head screws, Hyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM.


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_moreHyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM

expand_moreWhen reusing the screws

Figure 2. Cylinder head, Cylinder head screws, Hyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM, When reusing the screws.


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Heed bolt length. See figure 2.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreWith new screws


First stage	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m
Second stage	slacken
Third stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Fourth stage	90°90°90°
Fifth stage	90°90°90°

expand_moreCylinder head screws shank length (maximum)


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	3.91 in3.91 in99.4 mm


Valve cover	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreEngine block

expand_moreBalance shaft gear wheel

expand_moreHyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM


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_moreHyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM


Screws	33.19–36.88 lbf⋅ft33.19–36.88 lbf⋅ft45–50 N⋅m
Drive wheel toothed belt

expand_moreConnecting rod bearing

expand_moreHyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM


First stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Second stage	90°90°90°


Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	33.19–36.88 lbf⋅ft33.19–36.88 lbf⋅ft45–50 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	33.19–36.88 lbf⋅ft33.19–36.88 lbf⋅ft45–50 N⋅m

expand_moreAll other modifications


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°

expand_moreCrankshaft central screws


Hyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM	81.13–95.88 lbf⋅ft81.13–95.88 lbf⋅ft110–130 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	132.76–147.51 lbf⋅ft132.76–147.51 lbf⋅ft180–200 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	125.39–140.14 lbf⋅ft125.39–140.14 lbf⋅ft170–190 N⋅m
All other modifications	206.52–221.27 lbf⋅ft206.52–221.27 lbf⋅ft280–300 N⋅m

expand_moreCrankshaft pulley


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreDrive plate


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m


Flywheel	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m

expand_moreMain bearing

expand_moreHyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Second stage	90°90°90°


Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	55.32–62.69 lbf⋅ft55.32–62.69 lbf⋅ft75–85 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	55.32–62.69 lbf⋅ft55.32–62.69 lbf⋅ft75–85 N⋅m
All other modifications	95.88–103.26 lbf⋅ft95.88–103.26 lbf⋅ft130–140 N⋅m

expand_moreEngine control

expand_moreBalance shaft toothed belt tension pulley


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreBottom part of the control unit housing

expand_moreOn the engine block


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


Otherwise	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m

expand_moreCamshaft drive belt deflection pulley


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	22.13–29.5 lbf⋅ft22.13–29.5 lbf⋅ft30–40 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 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM	70.07–88.51 lbf⋅ft70.07–88.51 lbf⋅ft95–120 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	47.94–55.32 lbf⋅ft47.94–55.32 lbf⋅ft65–75 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	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	16.23–22.13 lbf⋅ft16.23–22.13 lbf⋅ft22–30 N⋅m

expand_moreInlet camshaft wheel


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	59–73.76 lbf⋅ft59–73.76 lbf⋅ft80–100 N⋅m

expand_moreOutlet camshaft wheel


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	59–73.76 lbf⋅ft59–73.76 lbf⋅ft80–100 N⋅m


Toothed belt guard	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreToothed belt tensioning roller


All Hyundai gasoline straight-4 2.4 Liters G4CS engines	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


Toothed belt tightener	16.23–20.65 lbf⋅ft16.23–20.65 lbf⋅ft22–28 N⋅m

expand_moreTop part of 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

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
Oil filter	16.23–18.44 lbf⋅ft16.23–18.44 lbf⋅ft22–25 N⋅m
Oil filter housing	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m

expand_moreOil pump


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m

expand_moreOil pump chain wheel

expand_more2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)


Cap	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 N⋅m
Nuts	36.88–44.25 lbf⋅ft36.88–44.25 lbf⋅ft50–60 N⋅m
Drive wheel toothed belt
Screws	25.08–29.5 lbf⋅ft25.08–29.5 lbf⋅ft34–40 N⋅m
Toothed wheel

expand_moreOil sump

expand_moreHyundai diesel straight-4 2.5 Liters D4CB 109 HP at 3800 RPM, 392 N⋅m at 2000 RPM

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


All other modifications	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreEngine management


Camshaft sensor	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Crankshaft sensor	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m
Glow plugs	11.06–14.75 lbf⋅ft11.06–14.75 lbf⋅ft15–20 N⋅m
Knock sensor	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Lambda sensor	29.5–36.88 lbf⋅ft29.5–36.88 lbf⋅ft40–50 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	40.57–47.94 lbf⋅ft40.57–47.94 lbf⋅ft55–65 N⋅m

expand_moreExhaust system

expand_moreCatalytic converter


2.4 with gasoline straight-4 2.4 L 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM engine (2000.3–2004.4)	22.13–29.5 lbf⋅ft22.13–29.5 lbf⋅ft30–40 N⋅m

expand_moreExhaust manifold

expand_moreHyundai gasoline straight-4 2.4 Liters G4CS 110 HP at 4500 RPM, 181 N⋅m at 2300 RPM


M8	18.44–22.13 lbf⋅ft18.44–22.13 lbf⋅ft25–30 N⋅m
M10	25.81–40.57 lbf⋅ft25.81–40.57 lbf⋅ft35–55 N⋅m


Hyundai diesel straight-4 2.5 Liters D4BH 98 HP	22.13–25.81 lbf⋅ft22.13–25.81 lbf⋅ft30–35 N⋅m
Hyundai diesel straight-4 2.5 Liters D4BH 99 HP	22.13–25.81 lbf⋅ft22.13–25.81 lbf⋅ft30–35 N⋅m
All other modifications	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m

expand_moreIgnition system


Spark plugs	14.75–22.13 lbf⋅ft14.75–22.13 lbf⋅ft20–30 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 Starex Box 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 Starex Box 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 Starex Box Van you're not only saving money, but also also improving your technical skills and learning something new.

2002 Hyundai Starex Box Van First generation Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Hyundai Starex Box Van First generation model years

Suggest edit