Torque Specifications - Battery System

Table 1. Torque Specifications: High Voltage Battery Assembly - Assembly, ECoat, Front Skid Plate, Enclosure (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts that attaches the front of the LH and RH front wheel liner to the HV battery	5 Nm (3.7 lbs-ft)	Cordless Ratchet/Impact Driver 10 mm deep socket (for installation only) Ratchet/torque wrench (for installation only)	Reuse
Bolts that attach the skid plate to the battery	13 Nm (9.6 lbs-ft)	Cordless Ratchet/Impact Driver ¼ in to 3/8 in adapter External Torx Plus EP10 6 in extension (for installation only) Ratchet/torque wrench (for installation only)	Reuse

Table 2. Torque Specifications: High Voltage Battery Assembly - Assembly, HV Battery, E3, AWD, 1PH (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
LH front footwell HV battery bolts	136 Nm (100.3 lbs-ft)	Torx Plus EP20 socket Cordless Ratchet/Impact Driver 3/8 in to ½ in adapter 3 in extension Ratchet/torque wrench	Reuse
Rear HV battery interior bolts	66 Nm (48.7 lbs-ft)	Cordless Ratchet/Impact Driver 16 mm deep socket Flex head ratchet/flex head torque wrench	Reuse
Bolt that secures the busbar cover access door Bolts that attach the charge port busbar kit to the HV header	9 Nm (6.6 lbs-ft)	Insulated 10 mm 12-point deep socket Insulated Ratchet/torque wrench Insulated 10 in extension	Reuse
Nut that attaches the positive LV output to the PCS cable	9 Nm (6.6 lbs-ft)	4 in extension Ratchet/torque wrench 13 mm socket	Replace
Bolts that attach the LH front wheel liner to the skid plate	5 Nm (3.7 lbs-ft)	10 mm deep socket Ratchet/torque wrench	Reuse
HV battery center bolts	34 Nm (25.1 lbs-ft)	Cordless Ratchet/Impact Driver Insulated 6 in extension External Torx Plus EP14 Flex head ratchet/flex head torque wrench	Reuse
Bolts that attach the LH and RH front support brackets to vehicle	110 Nm (81.1 lbs-ft)	Cordless Ratchet/Impact Driver 16 mm socket 3 in extension Ratchet/torque wrench	Reuse
Bolts (x16) that attach the HV battery to vehicle	35 Nm (25.8 lbs-ft)	3 in extension 13 mm socket Cordless Ratchet/Impact Driver Ratchet/torque wrench	Reuse
Bolts (x2) that attach the center ski cover to the HV battery	34 Nm (25.1 lbs-ft)	Ratchet/torque wrench External Torx Plus EP14	Reuse

Table 3. Torque Specifications: Disconnect, Pyro (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x2) that attach the pyrotechnic battery disconnect to the HV battery	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket Ratchet/torque wrench	Replace

Table 4. Torque Specifications: Ancillary Bay - FUSE, 63A, 700VDC, HT PMP, Tab (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nuts (x2) that attach the A/C compressor fuse to the ancillary bay bus	2.5 Nm (1.8 lbs-ft)	Insulated tools: 8 mm socket Ratchet/torque wrench	Replace

Table 5. Torque Specifications: Ancillary Bay - Assembly, Harness, 4P, 3PH, AC Filter (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x2) that attach the AC filter harness to the ancillary bay	10 Nm (7.4 lbs-ft)	External Torx E10 5-Lobe Insulated tools: Ratchet/torque wrench	Replace

Table 6. Torque Specifications: High Voltage Battery Assembly - Assembly, HV Header, 4P, 600V (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x2) that attach the PTC heater and A/C compressor HV header to the HV battery	10 Nm (7.4 lbs-ft)	4 in extension External Torx E10 5-Lobe Flex head ratchet/flex head torque wrench Electrical Protective Gloves	Reuse

Table 7. Torque Specifications: High Voltage Battery Assembly - Assembly, HV Header, HC - STAK 25, Battery (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nut that attaches the rear drive unit HV cable bracket to the HV battery	10 Nm (7.4 lbs-ft)	10 mm socket Cordless Ratchet/Impact Driver	Reuse
Bolts (x2) that attach the HV header to the HV battery	10 Nm (7.4 lbs-ft)	4 in extension External Torx E10 5-Lobe Ratchet/torque wrench	Reuse

Table 8. Torque Specifications: Ancillary Bay - Hinge, TRAY, HV Controller (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x2) that attach the HV controller hinge tray to the HV controller	5.5 Nm (4.1 lbs-ft)	External Torx E6 Insulated tools: Ratchet/torque wrench	Reuse
Bolts (x2) that attach the HV controller hinge tray to the ancillary bay cover	2 Nm (1.5 lbs-ft)	Insulated tools: Ratchet/torque wrench Torx T25 socket	Reuse

Table 9. Torque Specifications: Ancillary Bay - Assembly, Shunt (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the HV battery shunt to the busbar	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket Ratchet/torque wrench	Replace

Table 10. Torque Specifications: Ancillary Bay - Assembly, Probe LID, Ancillary Cover, HV Battery (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
5-lobe bolts (x2) that attach the HV probe cover to the Ancillary Bay cover	6 Nm (4.4 lbs-ft)	Safety Glasses Electrical Protective Gloves 4 in extension Skt, 1/4in Dr, 5-Lobe Torx Plus External Ratchet/torque wrench (for installation only)	Replace

Table 11. Torque Specifications: Passthrough - DCDC - LV (Cable Type) (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nut that attaches the positive output of power conversion system cable to the HV battery at the DCDC passthrough	9 Nm (6.6 lbs-ft)	4 in extension 13 mm deep socket	Replace
Bolts (x2) that attach the 12V DCDC passthrough to the ancillary bay	10 Nm (7.4 lbs-ft)	External Torx E10 5-Lobe Insulated tools: Ratchet/torque wrench	Reuse

Table 12. Torque Specifications: Ancillary Bay - PCBA, HV SYS Controller, E3 (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts that attach the high voltage controller to the hinge tray	2 Nm (1.5 lbs-ft)	Socket External Torx 1/4in Dr. E6 Insulated tools: Ratchet/torque wrench 2 in extension	Reuse

Table 13. Torque Specifications: High Voltage Battery Assembly -Assembly, Snap In Vent,Rear,HV Battery (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nuts that attach the LH vent assembly to the HV battery	10 Nm (7.4 lbs-ft)	Ratchet/torque wrench 10 mm socket 4 in extension	Reuse

Table 14. Torque Specifications: Ancillary Bay - Assembly, PACK Contactor, HV (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Patch bolt that attaches the negative pack contactor to the DC link busbar joint	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket Ratchet/torque wrench 6 in extension Electrical Protective Gloves Paint Pen Ratchet/torque wrench	Replace
Patch nut that attaches negative pack contactor to the HV battery tall silicon terminal	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket Ratchet/torque wrench 6 in extension Electrical Protective Gloves Ratchet/torque wrench Paint Pen	Replace
Nuts that attach the negative pack contactor to the ancillary bay	8 Nm (5.9 lbs-ft)	Insulated tools: Ratchet/torque wrench 6 in extension Magnetic pick up tool 1/4in Dr. Universal Joint x 10mm - 1057605-00-A Electrical Protective Gloves Paint Pen Ratchet/torque wrench	Reuse

Table 15. Torque Specifications: Ancillary Bay - Busbar, FastCharge, Input, NEG (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that secures the busbar cover access door	9 Nm (6.6 lbs-ft)	Insulated tools: Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Extension 1/4 Dr. Wobble 10.5" Electrical Protective Gloves Ratchet/torque wrench	Reuse
Bolts that attach the charge port busbar kit to the HV header	9 Nm (6.6 lbs-ft)	Insulated tools: Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Electrical Protective Gloves Ratchet/torque wrench	Reuse
Patch bolt that attach the negative inlet fast charge busbar to the fast charge contactor	5 Nm (3.7 lbs-ft) + 60 degrees 15 Nm (11.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace
Patch bolts that secure the negative and the positive fast charge busbar DC link sides	5 Nm (3.7 lbs-ft) + 60 degrees 15 Nm (11.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Electrical Protective Gloves Paint Pen Torque wrench with angle measurement	Replace
Patch bolts that attach the negative and positive fast charge busbar inlet side to the negative and positive DC input assembly busbar	5 Nm (3.7 lbs-ft) + 60 degrees 15 Nm (11.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket - 1057606-00-A Electrical Protective Gloves Paint Pen Ratchet/torque wrench Torque wrench with angle measurement	Replace
Bolts that secure the busbar DC input assembly to the ancillary bay	10 Nm (7.4 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench Electrical Protective Gloves Ratchet/torque wrench External Torx E10 5-Lobe - 1059330-00-B Paint Pen ¼ in to 3/8 in adapter	Replace
Bolts that attach the fast charge assembly to the ancillary bay	5.5 Nm (4.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 10 mm socket Electrical Protective Gloves Paint Pen	Reuse

Table 16. Torque Specifications: Ancillary Bay - Busbar, FastCharge, Input, POS (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that secures the busbar cover access door	9 Nm (6.6 lbs-ft)	Insulated tools: Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Extension 1/4 Dr. Wobble 10.5" Electrical Protective Gloves Ratchet/torque wrench	Reuse
Bolts (x2) that attach the charge port busbar kit to the HV header	9 Nm (6.6 lbs-ft)	Insulated tools: Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Electrical Protective Gloves Ratchet/torque wrench	Reuse
Patch bolts (x2) that attach the DC link side negative and positive fast charge busbars to the fast charge contactor	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace
Patch bolt that attaches the inlet side negative fast charge busbar and the negative DC input assembly busbar	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Electrical Protective Gloves Paint Pen Torque wrench with angle measurement	Replace
Patch bolt that attaches the inlet side positive fast charge busbar to the positive DC input assembly busbar	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket - 1057606-00-A Electrical Protective Gloves Paint Pen Ratchet/torque wrench Torque wrench with angle measurement	Replace
Bolts (x4) that secure the DC input busbar assembly to the Ancillary Bay	10 Nm (7.4 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench Electrical Protective Gloves Ratchet/torque wrench External Torx E10 5-Lobe - 1059330-00-B Paint Pen ¼ in to 3/8 in adapter	Replace
Bolts (x2) that attach the fast charge assembly to the Ancillary Bay	5.5 Nm (4.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 10 mm socket Electrical Protective Gloves Paint Pen	Reuse
Patch bolt that attaches the inlet side positive fast charge busbar to the fast charge contactor	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace

Table 17. Torque Specifications: Ancillary Bay - Busbar, FC Contactor To DC BUS, NEG (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that secures the busbar cover access door	9 Nm (6.6 lbs-ft)	Insulated tools: Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Extension 1/4 Dr. Wobble 10.5" Electrical Protective Gloves Ratchet/torque wrench	Reuse
Bolts (x2) that attach the charge port busbar kit to the HV header	9 Nm (6.6 lbs-ft)	Insulated tools: Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench - 1057602-00-A 10 mm 12-point deep socket - 1133768-00-C Electrical Protective Gloves Ratchet/torque wrench	Reuse
Patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace
Patch bolt that attaches the DC link side positive fast charge busbar to the fast charge contactor	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace
Patch bolt that attaches the inlet side negative fast charge busbar and the negative DC input assembly busbar	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Electrical Protective Gloves Paint Pen Torque wrench with angle measurement	Replace
Patch bolt that attaches the inlet side positive fast charge busbar to the positive DC input assembly busbar	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket - 1057606-00-A Electrical Protective Gloves Paint Pen Ratchet/torque wrench Torque wrench with angle measurement	Replace
Bolts (x4) that secure the DC input busbar assembly to the Ancillary Bay	10 Nm (7.4 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench Electrical Protective Gloves Ratchet/torque wrench External Torx E10 5-Lobe - 1059330-00-B Paint Pen ¼ in to 3/8 in adapter	Replace
Bolts (x2) that attach the fast charge assembly to the Ancillary Bay	5.5 Nm (4.1 lbs-ft)	Insulated tools: 4 in extension Ratchet/torque wrench 10 mm socket Electrical Protective Gloves Paint Pen	Reuse
Patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor	15 Nm (11.1 lbs-ft) - 180 degrees 5 Nm (3.7 lbs-ft) + 60 degrees	Insulated tools: 4 in extension Ratchet/torque wrench 13 mm socket Paint Pen Torque wrench with angle measurement	Replace

Table 18. Torque Specifications: Ancillary Bay - Assembly, FC Contactor, HV Battery (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Patch bolts that attach the DC link negative busbar, the DC link positive busbar, and the positive inlet fast charge busbar to the fast charge contactor	15 Nm (11.1 lbs-ft)	Insulated tools: Ratchet/torque wrench 4 in extension 13 mm socket Paint Pen Torque wrench with angle measurement	Replace
Bolts that attach the fast charge contactor to the lower fast charge insulator assembly	5.5 Nm (4.1 lbs-ft)	Insulated tools: Ratchet/torque wrench 4 in extension Socket External Torx 1/4in Dr. E8 Ratchet/torque wrench Paint Pen	Reuse

Table 19. Torque Specifications: Platter Enclosure Coolant Leak Test
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attach the lower rear edge of the LH wheel arch liner to the body	5 Nm (3.7 lbs-ft)	4 in extension 10 mm socket	Reuse

Table 20. Torque Specifications: Ancillary Bay - Assembly, Ancillary Cover, HV Battery (Remove and Install)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x3) that attach the ancillary bay cover to the high voltage controller	5 Nm (3.7 lbs-ft)	4 in extension Ratchet/torque wrench Torque wrench with angle measurement External Torx E10 5-Lobe Cordless Ratchet/Impact Driver	Reuse
Bolts (x18) that attach the ancillary bay cover to the HV controller	8 Nm (5.9 lbs-ft)	Ratchet/torque wrench 10 in extension External Torx E10 5-Lobe Cordless Ratchet/Impact Driver	Reuse	CAUTION Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head. Note Torque these fasteners in the sequence specified in the installation step. Note These bolts are attached to the ancillary bay cover.

Table 21. Torque Specifications: Ancillary Bay - HVCON, HDR, 2P, 600V, HVIL, BB (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches pyro disconnect to ancillary bay	9 Nm (6.6 lbs-ft)	4 in extension 13 mm socket	Replace
Bolt that attaches negative fastcharge busbar inlet side and negative DC input assembly busbar.	15 Nm (11.1 lbs-ft)	4 in extension 13 mm socket	Replace
Bolt that attaches positive fastcharge busbar inlet side and negative DC input assembly busbar	15 Nm (11.1 lbs-ft)	4 in extension 13 mm socket	Replace
Bolts that attach busbar DC input assembly to ancillary bay	10 Nm (7.4 lbs-ft)	4 in extension	Replace

Table 22. Torque Specifications: Ancillary Bay - Assembly, Insulator, LWR, FastCharge Assembly (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (x3) that attach the fast charge contactor to the lower fast charge insulator	5.5 Nm (4.1 lbs-ft)	Insulated tools: Ratchet/torque wrench 4 in extension Socket External Torx 1/4in Dr. E8	Reuse