Reference

Below is a selection of fastener sizes and general torque settings that may be useful.

Bolt Sizes:

(This is the best that I could do in getting the original spread sheet to fit on the blog page. It will be added to as I continue with the refurb).

Location	Bolt Type	Bolt Size	Quantity	Bolt Length	Washer	Nut
Random
Rear Hand Brake	Set Screw	M6	1	20mm	Spring
Middle Hand Brake	Set Screw	M8	1	40mm	Spring
Hand Brake Switch Nut		M12	1			Plain
Battery Box	Set Screw	M8	2	20mm	Spring (x2), Plain Large (x2)
Bonnet Hinge	Allen Head	M6	2	25mm	Plain (x2)
Lower Petrol Tank	Set Screw	M8	2	20mm	Plain (x2), Plain Large (x2)	Nyloc
Washer Resevoir Bracket	Set Screw	M6	2	20mm	Plain (x4)	Nyloc
Fuel Filter Bracket (to Body)	Set Screw	M8	1	16mm
Fuel Filter Bracket (to Filter)	Bolt	M8	1	45mm	Plain (x2)	Nyloc
Fuel Pump To Chassis Nuts		M5	2		Plain (x4)	Nyloc
Rear Brake Caliper Bolts	Allen Head	M10	4	30mm	Spring (x4)
3 Way Brake Union		M6	1		Spring	Nyloc
Radiator Bobbins (Engine Side)		M8	2		Spring (x2), Plain Large (x2)	Plain (x2)
Carbon Canister in Wheel Arch		M5	1		Penny	Nyloc
Front Hub Pinch Bolt	Set Screw	M12	2	70mm		Nyloc (x2)
100 amp Nuts		M5	2		Plain	Plain (x2)
Bonnet Adjuster Rubbers	Allen Head	M6	2	25mm
Expansion Tank	Set Screw	M8	1	20mm	Plain
	Set Screw	M6	1	25mm	Spring, Plain
Steering UJ’s	Bolt	M8	2	40mm		Nyloc (x2)
Air Filter Bolt	Set Screw	M8	1	25mm	Spring, Plain, Penny
Diff And ARB Mounts
Inner Drive Shaft to Diff	Allen Head	M10	12	60mm	Spring (x12)
Outer Drive Shaft to Hub	Allen Head	M10	12	60mm	Spring (x12)
Front ARB Clamps	Set Screw	M10	4	30mm	Spring (x4), Plain (x4)
O/S ARB Mount (Front)	Set Screw	M8	1	30mm	Plain (x6)	Nyloc (x2), Plain
(Rear)	Set Screw	M8	1	20mm
N/S ARB Mount (Front)	Set Screw	M8	1	30mm	Plain (x6)	Nyloc (x2), Plain
(Rear)	Set Screw	M8	1	20mm
O/S Diff Mount	Bolt	7/16″ (20tpi) UNF	1	3.5″	Plain (x2)	Nyloc
N/S Diff Mount	Bolt	7/16″ (20tpi) UNF	1	3.5″	Plain (x2)	Nyloc
Rear Diff Mount	Bolt	7/16″ (20tpi) UNF	1	3.5″	Plain (x2)	Nyloc
Rear Diff Plate to Diff	Allen Head	M10	2	40mm	Spring (x2)
	Allen Head	M10	2	30mm	Spring (x2)
Front Diff Mounts to Diff	Allen Head	M12	4	30mm	Spring (x4)	Plain (x4)
Prop Shaft to Diff	Set Screw	3/8″ (24tpi) UNF	4	1 1/4″		Nyloc (x4)
Interior Fixings/Seat Belts
Rear Seat Nuts		M8	4		Plain (x4), Plain Large (x4)	Nyloc
Front Seat Nuts		M8	4		Plain (x4)	Nyloc
Front Outside Seat Belt	Set Screw	7/16″ (20tpi) UNF	2	1.5″
Front Inner	Set Screw	7/16″ (20tpi) UNF	2	1.5″	Plain (x2)
Rear Lower Belt Reel	Bolt	7/16″ (20tpi) UNF	2	2″		Nyloc (x2)
Top Seat Belt	Set Screw	7/16″ (20tpi) UNF	2	1.5″	Wave (x2), Plain (x2)
Engine
Earth Bolt Front O/S Block	Set Screw	M8	1	20mm	Spring, Plain
Front/Engine cross Member	Bolt	M10	4	70mm	Plain (x8)	Nyloc (x4)
N/S Engine Mount to Chassis	Bolt	M10	2	80mm	Plain (x4)	Nyloc (x2)
O/S Engine Mount to Chassis	Bolt	M10	2	80mm	Plain (x4)	Nyloc (x2)
N/S Engine Mount Bracket	Set Screw	7/16″ (14tpi) UNC	2	3/4″	Spring (x2), Plain (x2)
	Set Screw	5/16″ (18tpi)	1	3/4″	Spring, Plain
O/S Engine Mount Bracket	Set Screw	7/16″ (14tpi) UNC	2	1″	Spring (x2), Plain (x2)
	Set Screw	5/16″ (18tpi)	1	3/4″	Spring, Plain
	Mushroom Screw	M5	2	25mm		Plain (x2)
O/S Engine Mount		M10	2		Plain (x2)	Nyloc (x2)
N/S Engine Mount		M10	2		Plain (x2)	Nyloc (x2)
Brake Pipe Block Surround	Set Screw	M6	4	20mm	Plain (x4)
Swirl Pot	Set Screw	M8	4	20mm	Plain (x8)	Nyloc (x4)
Gearbox
Middle G/Box Knob Connection	Bolt	M8	1	40mm	Plain (x2)	Nyloc
Rear G/Box Knob Connection	Bolt	M8	1	40mm	Plain (x2)	Nyloc
G/Box Mount Bracket	Set Screw	M10	2	30mm	Plain (x4)	Nyloc
G/Box Second Support	Bolt	M10	4	80mm	Plain (x8)	Nyloc
Rubber Gearbox Mount		M8	4		Spring (x4), Penny (x4)	Plain (x4)
Chassis Bolts
Front	Set Screw	M10	2	35mm	Plain (x2)
Rear	Set Screw	M10	2	35mm	Plain (x2), Spring (x2)
	Allen Head	M10	2	40mm	Spring (x2)
Centre Consol	Set Screw	M10	2	50mm	Plain (x2), Spring (x2), Penny (x2)
Longer Cabin	Set Screw	M10	10	35mm	Plain (x20), Spring (x10)
Shorter Cabin	Set Screw	M10	4	30mm	Plain (x8), Spring (x4)
Exhaust
Exhaust Clamp to Engine Block	Set Screw	5/16″ (18tpi) UNC	1	1″	Plain, Spring
Rear Exhaust Clamp		M6	2		Plain	Nyloc x2
Exhaust to Tray Bolts	Bolt	M10	3	60mm	Plain (x6)	Nyloc (x3)
Exhaust Tray to Chassis Bolts	Set Screw	M10	6	25mm	Spring (x6), Penny (x6)

N.B. The interior chassis bolts that came off my car were in 2 lengths as shown. This seems to be the classic case on initial assembly that the factory used whatever was available. You can choose whichever length you want as both fit with no problems in all the fastening locations.

Tools Needed:

The following is a selection of which bolts and nuts need what size sockets and spanners. Please don’t take this as gospel as it may have been the case that the sockets/spanners I used worked for that particular application (even they may not have been the actual correct size). If anything its a good starting point.

100amp Fuse Nuts	8mm Socket
3-Way Brake Nut	10mm Deep Socket
Allen Head Rear Chassis Bolts	6mm Allen Socket
Alternator Bolts	10mm Socket
Alternator Nuts	13mm Spanner
Battery Box Bolts	13mm Socket
Battery Terminals	14mm Spanner
Belt Tensioner Bracket Bolts	1/2 Imperial Socket
Belt Tensioner Nut	15mm Socket
Bonnet Hinge Allen Bolts	5mm Allen Socket
Brake Bleed Nipples	11mm Spanner
Brake Caliper Bolts	8mm Allen Socket
Brake Unions Female	14mm Spanner
Brake Unions Male	7/16 Imperial Spanner
Cable Ties	Side Cutters
Carbon Canister Nut	10mm Socket
Centre Console Screws	Phillips Screwdriver
Chassis Bolts	17mm Socket
Damper Bolts/Nuts	11/16 Imperial Socket
Diff Brackets to Chassis Bolts/Nuts	5/8 Imperial Socket/Spanner
Diff Mounting Chassis Bolts/Nuts	5/8 Imperial Socket/Spanner
Drive Shaft Allen Bolts	8mm Allen Socket
Engine Bay Cross Member Bolts/Nuts	17mm Socket/Spanner
Engine Bracket Mount Lower Bolts	5/8 Imperial Socket
Engine Bracket Mount Upper Bolt	1/2 Imperial Socket
Engine Rubbers to Chassis Bolts/Nuts	17mm Socket/Spanner
Engine Rubbers to Engine Mount Nuts	17mm Spanner
Exhaust Flange Bolt	5/16 Imperial Socket
Exhaust Plate to Chassis Bolts	17mm Socket
Exhaust Rubber Mount Bolts	17mm Socket
Exhaust Rubber Mount Nuts	17mm Spanner
Exhaust to Y-Piece Clamp	13mm Deep Socket
Expansion Tank Bolts	10mm & 13mm Sockets
Forward Hand Brake Bolt	13mm Spanner
Front ARB Bolts	17mm Socket
Front Diff Bracket Bolts/Nuts	10mm Allen Socket/19mm Spanner
Fuel Filter Bracket Bolt/Nut	13mm Socket/Spanner
Fuel Filter to Chassis Bolt	13mm Socket
Fuel Pump Nuts	8mm Deep Socket
Gear Box Mounting Rubber Nuts	13mm Spanner
Gear Box Remote Bolt/Nut	13mm Socket/Spanner
Gear Box Support Bracket Bolts/Nuts	17mm Socket/Spanner
Gear Box to Mount Nuts	17mm Spanner
Gear Stick Remote Bolt/Nut	13mm Socket/Spanner
Handbrake Grub Screws	2mm Allen Key
Jubilee Clips	Flat Blade Screwdriver
Lower Drop Link Nuts	17mm Socket
Lower Fuel Tank Clip/Hook Bolts	13mm Spanner
Lower Fuel Tank Clip/Hook Nuts	13mm Socket
Manilfold Bolts	14mm Spanner
Outrigger Chassis Bolts	17mm Socket
PAS Banjo Bolt	24mm Socket
PAS Reservoir Bracket	Adjustable Wrench
Plenum Allen Bolts	6mm Allen Socket
Prop Shaft Bolts/Nuts	9/16 Imperial Socket/Spanner
Radiator Bobbins	13mm Socket
Rear ARB Bracket Nuts	13mm Socket
Rear Diff Bracket Allen Bolts	8mm Allen Socket
Rear Exhaust Clamp Nuts	10mm Deep Socket
Rearward Hand Brake Bolt	10mm Spanner
Seat Belt Bolts	11/16 Imperial Socket
Seat Nuts	13mm Deep Socket
Steering Rack Bolts	13mm Socket
Stepper Motor	Adjustable Wrench
Swirl Pot Bolts	13mm Socket
Swirl Pot Nuts	13mm Spanner
Throttle Potentionmeter Screws	Flat Blade Screwdriver
Upper Drop Link Nuts	13mm Socket
Upper Fuel Tank Bracket Nuts	10mm Deep Socket
Upper Fuel Tank Clip/Hook Bolts	13mm Socket
Wash/Wipe Pump Bracket Bolts/Nuts	10mm Socket/Spanner
Water Pump P-Clip	10mm Socket
Wheel Arch Access Screws	Phillips Screwdriver
Wishbone Bolts/Nuts	3/4 Imperial Socket/Spanner
Y-Piece to Manifold Clamp Nuts	11mm Deep Socket

Torque Settings:

This is a general list that has been floating around a while on the various TVR forums and I thought I’d collate it all together. If the original owner/creator wants me to remove it I will do so immediately.

Component	Nm	Lb.ft
Crankshaft pulley bolt	270	200
Camshaft gear bolt	50	37
Camshaft thrust plate bolts	25	18
Rocker cover bolts			Note 1
Stage 1	4	3
Stage 2	8	6
Stage 3 – loosen and re-torque to:	8	6
Rocker shaft to cylinder head bolts	38	28
Cylinder head bolts			Note 1 & 2
Stage 1	20	15
Stage 2	Then 90 degrees
Stage 3	Further 90 degrees
Lifting eye to cylinder head bolts	40	30
Connecting rod bolts:
Stage 1	20	15
Stage 2	Further 80 degrees
Main bearing cap bolts – Nos. 1 to 8			Note 1
Stage 1 – initial torque	13.5	10
Stage 2 – final torque	72	53
Rear main bearing cap bolts – Nos. 9 and 10			Note 1
Stage 1 – initial torque	13.5	10
Stage 2 – final torque	92	68
Main bearing cap side bolts – Nos. 11 to 20			Note 1
Stage 1 – initial torque	13.5	10
Stage 2 – final torque	45	33
Flywheel bolts	80	59
Drive plate assembly bolts	45	33
Drive plate hub aligner to crankshaft socket head cap screws	85	63
Oil sump drain plug	45	33
Oil sump nuts and bolts	23	17	Note 1
Oil pump cover plate screws	4	3	Note 3
Oil pump cover plate bolt	8	6	Note 3
Spark plugs .	20	15
Timing cover/coolant pump to cylinder block bolts	22	16
Oil pick-up pipe to oil pump bolts	8	6
Oil pick-up pipe nut	24	18
Knock sensors to cylinder block	16	12
Camshaft sensor to timing cover bolt	8	6
Crankshaft position sensor bolts	6	4
Oil cooler connections	15	11
Note 1: Tighten in sequence
Note 2: Lightly oil threads prior to assembly
Note 3: Coat threads with Loctite 222 prior to assembly
General Torque Settings	Nm	lb.ft
M5	4	3
M6	6	4
M8	18	13
M10	35	26
M12	65	48
M14	80	59
M16	130	96
1/4 UNC/UNF	9	7
5/16 UNC and UNF	25	18
3/8 UNC and UNF	40	30
7/16 UNC and UNF	75	55
1/ 2 UNC and UNF	90	66
5/8 UNC and UNF	135	100
Component	ft lbs	Nm
Caliper to front upright	43	50
Track rod end to upright	30	40
Bottom balljoint to upright	60	81
Top balljoint to upright	60	81
Upper balljoint adapter pinch bolt	59	80
Top front wishbone to balljoint HSG	35	47
Bottom wishbone to balljoint HSG	Dec-15	16
Steering rack mountings	Dec-15	16
Steering UJ clamp bolts	Dec-15	16
Front & rear hub retaining nuts	229	310
Rear caliper to bearing carrier	40	54
Rear bearing carrier to upright	45	61
Differential front allen bolts	90	122-136
Differential bushes to chassis	48	65
Rear diff carrier to diff (cap Hd)	33	45
Top rear diff bush pinch bolt	45	61
All front wishbones to chassis	45	61
All rear wishbones to chassis	45	61-65
All rear wishbones to upright	45	61
All damper bolts	55	75
Roll bar mounting clamp to chassis	30	40
Drive shaft bolts to diff	32	38
Drive shaft bolts to axle shafts	32	38
Seat belt anchorage bolts	25	34
Wheel nuts	73	99
Brake master cyl to servo	15	20
Front crossmember	45	61
Gearbox crossmember	45	61

Diagrams:

I’m not too sure if these will help or not, but with my limited graphical skills these are the best I could come up with. The following show roughly the routes that some of the pipes/hoses/systems take on their way through the chassis:

Brake/Clutch Pipes

Brakes in Red and Clutch in Blue all meeting at the connection block on the inner wing off side just in front of the rear bulkhead

Fuel Pipes

From the tank to the fuel rail in Red, running down the chassis backbone and over the bell housing to the rail. From the rail back to the tank in Blue.

Carbon Canister

Carbon Canister pipe, exiting in the very forward lower off side section of the engine bay, coming across the front of the car and then heading down the chassis backbone to the fuel tank

Cooling System

• Red – Main cooling pipes/hoses
• Yellow – Water rail
• Green – Outline of radiator
• Grey – Expansion tank
• Blue- Water pump
• Black – Swirl pot
• Purple – Engine block

The cooling system diagram isn’t the easiest to follow so I’ll explain a little more. Starting at the bottom left of frame, the pipe proceeds out of the bottom of the radiator. This pipe then splits, with one side branching off to the water pump and the other to the water rail attached to the off side rocker cover. At the other end of the water rail are the two hoses leading to and from the heater matrix inside the near side wing. The final water rail connection then goes to the top of the engine block. Centre of frame is the pipe coming out of the engine to the top of the swirl pot, before exiting out the bottom of the pot and back to the other side (off side) of the radiator. Finally there is also the pipe from the expansion tank to the swirl pot as well. Definitely recommend zooming in on the picture.

If I can think of anymore potential diagrams then these will be included as and when.