Torque Specifications - Battery System

Table 1. Torque Specifications: Power Conversion System (Remove and Install)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nuts that attach the positive/negative terminal of the DCDC harness to the positive/negative DCDC passthrough busbar	4.5 Nm (3.3 lbs-ft)	8 mm socket 4 in extension Ratchet/torque wrench	Reuse
Bolts that attach the power conversion system to the HV battery	6 Bolt Power Conversion System: 6 Nm (4.4 lbs-ft) 5 Bolt Power Conversion System: 18 Nm (13.3 lbs-ft)	Insulated tools: 8 mm socket 10 in extension Ratchet/torque wrench	Reuse	Upon installation, mark each bolt with a paint pen

Table 2. Torque Specifications: GUID-A6E89225-C5E9-4EA0-BF68-441A5866D198.html
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the DC inlet positive busbar to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolt that attaches the DC inlet negative busbar to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x2) that attach the FC positive outlet jumper to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x2) that attach the FC negative outlet jumper to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x3) that attach the HV battery fast charge contactor to the ancillary bay	5.5 Nm (4.1 lbs-ft)	Insulated tools: Socket External Torx 1/4in Dr. E8 Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Reuse

Table 3. Torque Specifications: GUID-5E897C7B-7F14-4669-A6C0-3DADF1B8FCF6.html
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the AC filter harness to the negative DC inlet busbar	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolt that attaches the AC filter harness to the positive DC inlet busbar	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x2) that attach the FC positive outlet jumper to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x2) that attach the FC negative outlet jumper to the ancillary bay	15 Nm (11.1 lbs-ft) -180 deg 5 Nm (3.7 lbs-ft) +60 deg	Insulated tools: 13 mm socket Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Replace
Bolts (x3) that attach the HV battery fast charge contactor to the ancillary bay	5.5 Nm (4.1 lbs-ft)	Insulated tools: Socket External Torx 1/4in Dr. E8 Magnetic pick up tool Extension 1/4 Dr. Wobble 10.5" Ratchet/torque wrench	Reuse

Table 4. Torque Specifications: Controller - High Voltage (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts that attach the HVC to the ancillary bay cover	5 Nm (3.7 lbs-ft) +30 deg	External Torx E10 4 in extension Ratchet/torque wrench	Replace
Screws that attach the HVC tray to the ancillary bay	2 Nm (1.5 lbs-ft)	Insulated tools: Torx T25 socket 10 in extension Magnetic pick up tool Wiha TorqueVario-S 0.8 Nm - 2.0 Nm screwdriver (installation only) Ratchet/torque wrench	Reuse	Not necessary to remove these fasteners if only removing the HVC
Bolts that attach the HVC tray to the HVC	2 Nm (1.5 lbs-ft)	Insulated tools: External Torx E6 2 in extension Ratchet/torque wrench	Reuse

Table 5. Torque Specifications: Pyrotechnic Battery Disconnect (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the pyrotechnic battery disconnect to the HV battery	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket 6 in extension Ratchet/torque wrench	Replace

Table 6. Torque Specifications: Skid Plate - HV Battery - Rear (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the rear skid plate to the lower HV battery	13 Nm (9.6 lbs-ft)	External Torx Plus EP10 4 in extension Ratchet/torque wrench	Reuse
Nut that attaches the rear skid plate to the upper HV battery	13 Nm (9.6 lbs-ft)	10 mm socket 4 in extension Ratchet/torque wrench	Reuse
Bolts that attach the rear skid plate to the upper HV battery	30 Nm (22.1 lbs-ft)	13 mm socket 3 in extension Ratchet/torque wrench	Reuse

Table 7. Torque Specifications: Cover - Ancillary Bay (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Nut that attaches the positive 12V output cable to the DCDC passthrough	9 Nm (6.6 lbs-ft)	13 mm 12-point deep socket 3 in extension Ratchet/torque wrench	Replace	Note Mark the fastener with a paint pen after torquing.
Bolt that attaches the ancillary bay cover to the high voltage controller	5 Nm (3.7 lbs-ft) +30 deg	External Torx E10 4 in extension Ratchet/torque wrench Torque wrench with angle measurement	Replace
Bolt attaches the ancillary bay cover to the HV battery	8 Nm (5.9 lbs-ft)	External Torx E10 5-Lobe 4 in extension Ratchet/torque wrench	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 8. Torque Specifications: Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolts (EPL10 or EPR10) that attach the ancillary bay cover to the HV battery	5 Nm (3.7 lbs-ft)	External Torx E10 5-Lobe 4 in extension Ratchet/torque wrench	Reuse Replace	Note Torque these fasteners in the sequence specified in the installation step. Note These bolts are attached to the ancillary bay cover.
Bolts (EPL10 or EPR10) that attach the charge port header to the ancillary bay cover	10 Nm (7.4 lbs-ft)	External Torx E10 5-Lobe 4 in extension Flex head ratchet/flex head torque wrench	Reuse
Bolts (EPL10) that attach the 3-phase header to the ancillary bay	6 Nm (4.4 lbs-ft)	External Torx E10 5-Lobe 4 in extension Flex head ratchet/flex head torque wrench	Reuse
Bolts (E10 or EPL14) that attach the ancillary bay cover to the HV controller	10 Nm (7.4 lbs-ft)	External Torx E10 5-Lobe Socket 3/8 in EP14 4 in extension ¼ in to 3/8 in adapter Ratchet/torque wrench
Bolts (T20) that attach the PCS LVDC header to the ancillary bay cover	2.5 Nm (1.8 lbs-ft)	Torx T20 socket 4 in extension Flex head ratchet/flex head torque wrench

Table 9. Torque Specifications: Cover - HV Probe - HV Battery (Remove and Replace)
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the HV probe cover to the ancillary bay cover	6 Nm (4.4 lbs-ft)	External Torx E10 5-Lobe 4 in extension Ratchet/torque wrench	Replace	Note Mark the fastener with a paint pen after torquing.

Table 10. Torque Specifications: Platter Enclosure Coolant (Drain and Refill)
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)	Clip pry tool Cordless Ratchet/Impact Driver 4 in extension 10 mm socket	Reuse

Table 11. Torque Specifications: GUID-F9F2F7C5-F314-44E5-AE77-3F0C7AD4AAE6.html
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the positive pack contactor to the positive busbar Nut that attaches the positive pack contactor to the module 4 rear terminal	9 Nm (6.6 lbs-ft)	Insulated tools: Ratchet/torque wrench 6 in extension 13 mm socket Paint Pen Electrical Protective Gloves	Replace	Bolt: 1104475-00-F Nut: 1104654-00-B
Nuts that attach the positive pack contactor to the ancillary bay	8 Nm (5.9 lbs-ft)	Insulated tools: Ratchet/torque wrench Flexible Magnet Extension 1/4 Dr. Wobble 10.5" 10 mm socket Insulated Magnetic Pick Up Tool - 1057607-00-A Electrical Protective Gloves Paint Pen	Reuse
Bolt that attaches the negative pack contactor to the DC link busbar joint Nut that attaches the negative pack contactor to HV battery tall silicon terminal	9 Nm (6.6 lbs-ft)	Insulated tools: Ratchet/torque wrench 6 in extension 13 mm socket Electrical Protective Gloves Paint Pen	Replace	Bolt: 1104475-00-F Nut: 1104654-00-B
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 10 mm socket 10 mm 12-point deep socket Insulated Magnetic Pick Up Tool - 1057607-00-A Electrical Protective Gloves Paint Pen	Reuse

Table 12. Torque Specifications: GUID-7111B1DF-6613-4C9E-9091-8C06107B6EAD.html
Description	Torque Value	Recommended Tools	Reuse/Replace	Notes
Bolt that attaches the shunt assembly to the ancillary bay	9 Nm (6.6 lbs-ft)	Insulated tools: 13 mm socket 2 in extension	Replace