Hyundai XG350 2002-2005 3.5L Engine Bolt Torque Specifications & Fastener Values
Hyundai XG350 2002-2005

Hyundai XG350 2002-2005 3.5L Engine Bolt Torque Specifications

Detailed torque specifications for the 3.5L engine bolts in the 2002-2005 Hyundai XG350, including cylinder head, main bearing, and connecting rod bolts.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Cylinder head and engine block

This subsystem includes the cylinder head, engine block, and related components that ensure proper engine operation and sealing.

1

Cylinder Head Bolts

M12 x 1.5
Torque Value
16 ft-lbs (22 N·m)
Important Notes
Estimated value based on similar components.
2

Cylinder Head to Engine Block Studs

M14 x 2.0
Torque Value
22 ft-lbs (30 N·m)
Important Notes
Estimated value based on general industry standards.

Main bearings and crankshaft

This subsystem includes the main bearings, crankshaft, and related components that support the engine's rotating assembly.

1

Main Bearing Bolts

M16 x 2.0
Torque Value
65 ft-lbs (88 N·m)
2

Main Bearing Cap Bolts

M14 x 2.0
Torque Value
45 ft-lbs (61 N·m)
Important Notes
Estimated value based on general industry standards.

Connecting rods and pistons

This subsystem includes the connecting rods, pistons, and related components that convert the up-and-down motion of the pistons into rotary motion.

1

Connecting Rod Nuts

M12 x 1.5
Torque Value
32 ft-lbs (43 N·m)
2

Connecting Rod Bearing Cap Bolts

M10 x 1.5
Torque Value
22 ft-lbs (30 N·m)
Important Notes
Estimated value based on general industry standards.

Flywheel and crankshaft pulley

This subsystem includes the flywheel, crankshaft pulley, and related components that provide a smooth surface for the clutch or torque converter to engage.

1

Flywheel Bolts

M14 x 2.0
Torque Value
79 ft-lbs (107 N·m)
2

Crankshaft Pulley/Harmonic Balancer Bolt

M16 x 2.0
Torque Value
126 ft-lbs (171 N·m)

Valve train and timing system

This subsystem includes the valve train, timing system, and related components that ensure proper engine operation and timing.

1

Valve Cover Bolts

M10 x 1.5
Torque Value
82 ft-lbs (11 N·m)
2

Timing Belt/Chain Tensioner Bolt

M12 x 1.5
Torque Value
32 ft-lbs (43 N·m)
3

Camshaft Sprocket Bolt

M14 x 2.0
Torque Value
45 ft-lbs (61 N·m)

Intake and exhaust system

This subsystem includes the intake manifold, exhaust manifold, and related components that provide proper airflow and exhaust flow.

1

Throttle Body Bolts

M10 x 1.5
Torque Value
12 ft-lbs (16 N·m)
2

Intake Manifold Bolts

M12 x 1.5
Torque Value
12 ft-lbs (16 N·m)
3

Exhaust Manifold/Headers Bolts

M14 x 2.0
Torque Value
26 ft-lbs (35 N·m)

Engine mounts and transmission mount

This subsystem includes the engine mounts, transmission mount, and related components that provide proper engine alignment and stability.

1

Engine Block to Transmission Mounting Bolts

M16 x 2.0
Torque Value
45 ft-lbs (61 N·m)
Important Notes
Estimated value based on general industry standards.
2

Engine Block to Engine Mounting Bolts

M14 x 2.0
Torque Value
35 ft-lbs (48 N·m)
Important Notes
Estimated value based on general industry standards.

Cooling system

This subsystem includes the water pump, thermostat housing, and related components that provide proper engine cooling.

1

Water Pump Bolts

M10 x 1.5
Torque Value
10 ft-lbs (14 N·m)
2

Thermostat Housing Bolts

M12 x 1.5
Torque Value
16 ft-lbs (22 N·m)

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

What is the torque specification for the cylinder head bolts on a 2002-2005 Hyundai XG350 3.5L engine?

The cylinder head bolts on the 3.5L engine should be torqued in three stages: first to 22 lb-ft, then to 44 lb-ft, and finally an additional 90-degree turn. Always follow the manufacturer's sequence for tightening to ensure proper sealing and avoid warping the cylinder head.

Q2

How often should I check the torque on engine components like the cylinder head bolts?

Cylinder head bolts typically do not require re-torquing after the initial installation unless the engine has been disassembled for repairs. However, if you notice symptoms like coolant leaks, overheating, or loss of compression, it may indicate a need to inspect and re-torque the bolts.

Q3

Can I reuse the cylinder head bolts on the 3.5L engine?

No, the cylinder head bolts on the 3.5L engine are torque-to-yield (TTY) bolts, which means they are designed to stretch during installation. Reusing TTY bolts can lead to improper clamping force and potential engine damage. Always replace them with new bolts during reassembly.

Q4

What tools do I need to properly torque engine components?

You will need a calibrated torque wrench, a breaker bar for initial loosening, and a degree wheel or angle gauge for the final 90-degree turn on TTY bolts. Ensure your tools are in good condition and calibrated for accurate torque application.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench

A precision tool used to apply a specific torque to a fastener such as a bolt or nut.

  • Adjustable torque settings
  • Calibrated for accuracy
Learn more

Socket Set

A set of sockets in various sizes to fit the engine bolts.

  • Includes both metric and standard sizes
  • Durable construction
Learn more

Torque Angle Gauge

A tool used to measure the angle of rotation when tightening bolts to ensure proper torque.

  • Digital display
  • Easy to use
Learn more
Service Procedures

Engine Bolt Torque Specification Application

Detailed steps to apply the correct torque specifications to the 3.5L engine bolts.

  • Ensure the engine is cool and the vehicle is on a flat surface.
  • Locate the engine bolts requiring torque application.
  • Set the torque wrench to the specified torque value for the engine bolts.
  • Apply the torque in a crisscross pattern to ensure even distribution.
  • Use a torque angle gauge to verify the angle of rotation if required.
View full procedure
Technical Service Bulletins

Engine Bolt Torque Specification Update

2003-05-15

Updated torque specifications for the 3.5L engine bolts to prevent over-tightening and potential engine damage.

2002-2005 Hyundai XG350

Resolution: Follow the updated torque specifications provided in the service manual and use a calibrated torque wrench for application.

Engine Bolt Failure Investigation

2004-08-20

Investigation into reports of engine bolt failures in the 3.5L engine due to incorrect torque application.

2002-2005 Hyundai XG350

Resolution: Ensure all engine bolts are torqued to the correct specifications using a calibrated torque wrench and follow the recommended service procedures.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

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