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PostPosted: Thu Sep 25, 2014 4:01 pm 
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Certified Bonneville Nut
Certified Bonneville Nut
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Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4680
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
This seems to come up from time to time for me, so I'd like to start a list of the 'hard to find' information for parts and fasteners for the H-body, including things like 'universal' replacements or other non-googleable info. The goal here is not to list everything in the parts store, rather be a resource for us modders. There are a lot of holes in the data here, any contributions/corrections welcome! This started out as a list for replacing rusted bolts with stainless steel, or extreme corrosion resistance coated bolts. Some of these still need to be double checked.

When replacing bolts with non-factory, understanding bolt grade and the joint it's being used on is very important. Most of the fasteners on these cars are (SAE) grade 5 / (metric) class 8.8 equivalent and are not under significant load. These can be safely replaced with an 18-8 or A2 stainless steel bolt, which are little less than grade 5. A class 9.8 fastener is typically under load but can be replaced with 17-4 PH stainless. However you should take notice of any fastener that is marked with a 10.9 (you won't see grade 8 outside of the engine). Those fasteners can not be replaced with any stainless steel fastener, only use a class 10.9 replacement. These bolts are always marked on the head. They can be replaced by an alloy steel if you still want the finished look of a socket head, these are stronger than grade 8 and the same as metric class 12.9, which are available with a corrosion resistant zinc coating. It should also be noted that it is critical to torque an alloy steel fastener to the correct pre-load - otherwise they can fatigue and break. Don't use an alloy bolt on the rotating assembly, there's enough proper aftermarket available for any bolt upgrades you need there anyway.

Feel free to contribute or correct any information here.


3800 Series 2/3 engine bolt sizes:
Main bearing cross-bolts: M8x1.25 @ 50mm (6x) * **
Oil pan to block: 1/4-20 @ 1" (20x) **
Header to head bolts: 5/16-18 @ 1" (9x) - - @ 1.5" (3x)
engine lift bracket to block: 5/16-18 @ 5/8" (2)
Intake manifold to head bolts: 5/16-18 @ 1.125" (12)
Timing cover to block bolts: 5/16-18 @ 3.125" (6) - - @1.5" (4) **
Valve cover bolts: 1/4-20 @ 5/16"x5/8" shoulder (12)
Supercharger to LIM: M8x1.25 @ 40mm (9) - - @ 60mm (1) - - @ 80mm (1)
SC snout to SC: M8x1.25 @ 50mm (9)
Sensors to throttle body: M4x0.7 @ 12mm (2) - - @16mm (4)
Bracket to TB: M6x1 @ 20mm (2)
Ignition coil to control module: M5x0.8 @ 45mm (6)
PCV Cover to SC: M6x1 @ 16mm (2)
Vac port to SC: M6x1 @ 20mm (2)
SC bypass valve to SC: M6x1 @ 16mm (2)
Oil filter bracket to timing cover: 5/16-18 @ 1.5" (4)
A/C bracket bolts: M12x1.75 @ 35mm (3) - - 3/8-16 @ 2" (1)
water pump bolts: 1/4-20 @ 1.125" (4) - - 5/16-18 @ 3" (4)
Cam sensor bolt: 1/4-20 @ 5/8" (1)
Engine mount bracket bolts:
Thermostat cover: M8x1.25 @ 30mm (2)
Water pump pulley: M6x1 @ 12mm (4)
LIM water cover: M6x1 @ 20mm (2)
PCV cover: M8x1.25 @ 16mm (2)
Heater hose elbow brackets: M6x1 @ 16mm (2)
Evap Sensor bracket: M6x1 @ 16mm (1)
EGR heat shield: M6x1 @ 16mm (1)
SC tensioner bracket: 3/8-16 @ 1.5" (1) - - @ 2" (1) - - @ 2.5" (1)
Main belt tensioner bracket: 3/8-16 @ 2.5" (3)
PS trans bracket: 3/8-16 @ 3/4" (2)
MAP sensor: M5x0.8 @ 30mm (2 or 4)
Ignition Coil to bracket: M5x0.8 @ 40mm (6)
Power steering to block (bracket): M8x1.25 @ 75mm (2)
Power bracket to block ('00+): M8x1.25 @ 80mm (1) - - @ 25mm (2)
Engine bracket to block: M10x1.5 @ 70mm (1) - - @ 75mm (1) - - M12x1.75 @ 130mm (1)
Altenator: M10x1.5 @ 60mm (2)
Vac Tee to SC: M8x1.25 @ 20mm (2)
A/C compressor to bracket: M10x1.5 @ 60mm (3)
Lower SC idler pulley: M10x1.5 @ 25mm (1)
Fuel rail to SC: M8x1.25 @ 10mm (1)
Starter motor: M10x1.5 @ 50mm (1) - - @ 115mm (1)
Battery cable to block: M10x1.5 @ 20mm (1)
EGR to block: 3/8-16 @ 1" (2)
EGR to manifolds: M6x1 @ 25mm (2)


*Use class 12.9 or better only
**Use sealant at the head of the bolt to prevent oil dripping past the head


Series 1 O-ring sizes
*quick note about O-rings - Generally accepted designs consider a 10-40% compression in the direction of the seal. For Radial (think piston rings) the ID should be sized for a 1-5% compression on the ID, then the cross section or OD calculated to get the compression. Axial o-rings (like the two between the UIM and LIM) compression is calculated against the cross section thickness of the O-ring, OD is fitted to match, and ID has slight clearance to the hole. Best way to calculate an O-ring is to measure the sealing surfaces on the parts themselves to find the nominal ID and OD and calculate the range of O-rings that fit from there. Note that it is very difficult to measure accurately an o-ring itself, because it's common for automotive applications to have permanent deformation. Stay away from the cheap harbor freight (or online equivalents) as they have excessive flash and won't seal properly.
O-ring sizes have a standard "dash number" for their size, material should be selected based on chemicals and temperatures involved. Theoringstore.com has all the info you need to choose. Keep in mind most engine O-rings need to be compatible with oil, fuel, 300F in addition to the fluid they are supposed to seal. I've listed the closest standard dash size orings with actual measured dimensions following (note that measurements are based off worn out o-rings).
Upper coolant heater hose (LIM): -016 (5/8ID, 3/4OD, 1/16CS)
Lower coolant heater hose (WP): -209 (11/16ID, 29/32OD, 7/64CS)
Bypass nipple: -213 (29/32ID, 1-5/32OD, 1/8CS)
Throttle Body (between plenum and LIM): -112 (1/2ID, 47/64OD, 7/64CS)
(AM) Fuel Pressure line at fuel rail: -011 (19/64ID, 27/64OD, 1/16CS)
(AM) Fuel Return line at fuel rail: -010 (15/64ID, 11/32OD, 1/16CS)

Series 2 O-ring sizes (note, dimensions taken from GM part number when available)
Coolant elbow O-rings:
3x -115 (11/16 ID, 7/8 OD, 3/32 CS) (GM 25537068)
1x -117 (13/16 ID, 1 OD, 3/32 CS) (GM 24502846)
Heater Hose elbow (adapter) o-rings:
2x -118 (7/8 ID, 1-1/16OD, 3/32 CS) (GM 24502375)
Vacuum Tee oring:
1x -118 (7/8 ID, 1-1/16OD, 3/32 CS) (GM 24503492)

4T65e bolt sizes:
Pan to case: M6x1 @ 16mm (20)
Cover to case: M8x1.25 @ 20mm (4) - - @ 25mm (14)
Accumulator to case: M6x1 @ 20mm (3)
Trans to engine block: M12x1.75 @ 50mm (5) - - 5mm thick M12 washer

Misc Engine hardware
Supercharger coupler: Dorman 917-022
Evap purge tube with 180 elbows on both ends (L67): 24506665
Coolant elbow O-rings: (x3) -115 (11/16 ID, 7/8 OD, 3/32 cross-section O) (GM 25537068 is 17.02mm ID and 2.54mm thickness)
(x1) -117 (13/16 ID, 1 OD, 3/32 cross-section O) (GM 24502846 is 20.32mm ID and 2.54mm thickness)

Front Brake hardware
GXP banjo bolts: M10x1.0 @ 27.5mm Dorman 13912
Bracket to ABS: M6x1.0 @ 22mm (3) - - @ 12mm (2)
M8x1.25 @ 60mm (1) - - @ 20mm (2) - - @ 15mm (1)

Brake line to brake hose: M10x1.0 (3/16 line) BLF-39C-5
Brake line to ABS: M12x1.0 (3/16" line) BLF-48C-5
Master cylinder to ABS: M12x1.0 (1/4" line, all 4 same) NAPA 641-3329

Rear Brake hardware
GXP banjo bolts: M10x1.5 @ 22.8mm Dorman 13940
Brake line to ABS: M10x1.0 (3/16" line)
Brake line to Proportioning valve: M12x1.0 (inlet) M10x1.0 (outlet) (3/16" line)
Brake line to brake hose: M10x1.0 (3/16 line)

Front suspension hardware
'00+ caliper bracket to knuckle: M14x2.0 @ 40mm (4)
Sway bar center link to subframe: M10x1.5 @ 40mm(4)
Wheel bearing to knuckle: M12x1.75 @ 50mm (6)


C/V axles
'86-'91 RH/LH center shaft OD: 26mm / 26mm
'97-'99 RH/LH center shaft OD: 26mm (28mm HD) / 26mm
26mm center shaft outboard spline: 32 spline, involute rolled (unknown pressure angle, likely 30), 24.5 minor diameter.

Rear suspension hardware
Air line repair kit: Monroe AK29, uses 1/8" nylon tube and OE connectors
'86-'99 rear end links: M8x1.25 @ (80mm unthreaded) alt: 3/8-16 @ (3.125" unthreaded)


Fuel system hardware
Push to connect fittings for nylon line: 3/8" Dorman 800-193; 5/16" Dorman 800-191
Steel quick disconnect ends: 1 each tube (5/16" and 3/8") with quick disconnect on each end - Dorman 800-159
Quick Disconnect O-ring: for 3/8" 3/8 x 1/2 x 1/16 - - for 5/16" 5/16 x 7/16 x 1/16 (1x HNBR and 1x Viton in each connector)

_________________
Blow all the things! Wait, I meant boost. Boost!
Image

The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap
'99 Montana - top swap 3800

Current project:
upkeep on K2500 and 97 LeSabre

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

RIP:
'86 LeSabre - pictures
'93 SE - L67


Last edited by MattStrike on Thu Sep 10, 2020 10:55 pm, edited 16 times in total.

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PostPosted: Sat Oct 11, 2014 11:28 pm 
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Certified Bonneville Nut
Certified Bonneville Nut

Joined: Thu May 22, 2008 11:14 pm
Posts: 3351
Location: Racine, Wisconsin
Year and Trim: 97.2 40th SLE
68 w/400
94 SSEi
Great info Matt!

Tech Info, anyone?

_________________
Clay
1997.2 40th SLE-138k
1968 Bonneville 400ci w/TH-400-40k
1999 GMC Suburban SLT-191k
2005 Escalade 253k-GINA


nos4blood70 wrote:
Literally, cars are drugs.


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PostPosted: Sun Oct 12, 2014 11:31 pm 
Offline
Certified Bonneville Nut
Certified Bonneville Nut
User avatar

Joined: Tue Aug 25, 2009 8:32 pm
Posts: 4680
Location: Dearborn, MI
Year and Trim: '93 SSEi
'05 STS-4
'97 Camaro
'97 LeSabre
I've been updating this since I've originally posted. I plan to continue adding info as I find useful.

_________________
Blow all the things! Wait, I meant boost. Boost!
Image

The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap
'99 Montana - top swap 3800

Current project:
upkeep on K2500 and 97 LeSabre

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

RIP:
'86 LeSabre - pictures
'93 SE - L67


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