This procedure covers the removal and replacement of both positive and negative battery cables on the 2023 Chevrolet Bolt EUV, including proper disconnection sequence and torque specifications.

Warnings

Tools required

Parts

• Positive battery cable × 1 — Use OEM specification
• Negative battery cable × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all electrical accessories and remove key fob from vehicle
3. Wait at least 2 minutes after turning off vehicle to allow systems to enter sleep mode
4. Open hood and locate 12V battery in engine compartment (passenger side)
5. Inspect battery cables for routing and connection points before removal
6. Take photos of cable routing for reference during reinstallation

Procedure

1. 1

   Disconnect negative battery cable
   Using a 10mm wrench, loosen the negative (-) battery terminal bolt. Remove the cable from the battery terminal and secure it away from the battery post using a non-conductive tie or tape. Ensure the cable cannot accidentally contact the terminal.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Disconnect positive battery cable
   Using a 10mm wrench, loosen the positive (+) battery terminal bolt. Remove the cable from the battery terminal and secure it away from the battery post. Cover the terminal end with a non-conductive material to prevent accidental contact.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
3. 3

   Remove battery hold-down if necessary
   If the battery hold-down bracket interferes with cable removal, use a 12mm socket to remove the battery hold-down bolt. Lift the hold-down bracket off the battery and set aside.
   Torque spec

   Battery Hold-Down Bolt11 Nm (8 lb-ft)
4. 4

   Disconnect ground cable connections
   Trace the negative cable to all grounding points on the chassis and engine. Remove ground cable bolts and ground strap bolts using appropriate sockets. Note the exact location and orientation of each ground connection for proper reinstallation.
   Torque spec

   Ground Cable Bolt14 Nm (10 lb-ft)

   Ground Strap Bolt14 Nm (10 lb-ft)
5. 5

   Remove positive cable routing fasteners
   Follow the positive cable routing and remove any bracket bolts or connector screws securing the cable along its path. Keep all fasteners organized by location for reinstallation.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)

   Connector Screws4 Nm (3 lb-ft)
6. 6

   Disconnect positive cable at power distribution
   Locate where the positive cable connects to the main power distribution point or fuse box. Remove the mounting bolts securing the cable terminal. Carefully extract the cable from the connector housing.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Remove old battery cables
   Carefully remove both cables from the vehicle, noting their exact routing path, especially where they pass through grommets, clips, or protective sheathing. Inspect the routing path for any damage or debris.
   ℹ️Take additional photos or make notes of cable routing through tight spaces or areas with limited visibility.
8. 8

   Clean all connection points
   Use a wire brush or battery terminal cleaner to clean the battery posts, all ground contact points on the chassis and engine, and the power distribution connection points. Remove all corrosion, dirt, and oxidation. Clean surfaces with baking soda solution if corrosion is present, then dry thoroughly.
   Torque spec

   Ground Strap Bolt14 Nm (10 lb-ft)
9. 9

   Route new positive cable
   Route the new positive cable exactly as the original was positioned, ensuring it passes through all original grommets and clips. Verify the cable has adequate slack and does not contact sharp edges or hot surfaces. Secure with bracket bolts as originally positioned.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Connect positive cable at power distribution
    Install the positive cable terminal at the power distribution point or fuse box. Ensure the terminal is fully seated and properly aligned before tightening mounting bolts to specification.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Route and connect negative cable
    Route the new negative cable through its original path. Connect all ground points to the chassis and engine, ensuring clean metal-to-metal contact at each grounding location. Tighten ground cable bolts and ground strap bolts to specification in sequence from furthest to closest to battery.
    Torque spec

    Ground Cable Bolt14 Nm (10 lb-ft)

    Ground Strap Bolt14 Nm (10 lb-ft)
12. 12

    Reinstall battery hold-down
    If removed, reinstall the battery hold-down bracket over the battery. Tighten the hold-down bolt to specification, ensuring the battery is secure but not over-compressed.
    Torque spec

    Battery Hold-Down Bolt11 Nm (8 lb-ft)
13. 13

    Connect positive battery terminal
    Remove any protective covering from the positive cable terminal. Place the positive cable terminal onto the positive (+) battery post. Apply dielectric grease if desired. Tighten the terminal bolt to specification using a torque wrench.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
14. 14

    Connect negative battery terminal
    Place the negative cable terminal onto the negative (-) battery post. Apply dielectric grease if desired. Tighten the terminal bolt to specification using a torque wrench. Verify both terminals are tight and cannot be moved by hand.
    ℹ️Vehicle systems will power on when negative terminal is connected. This is normal.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all cable routing matches original configuration and cables are secured in all clips and brackets
2. Ensure no cables contact moving parts, sharp edges, or heat sources
3. Confirm all ground connections have clean metal-to-metal contact
4. Double-check that all torque specifications have been met

Verification

• Turn ignition on and verify all dashboard indicators illuminate normally
• Check for any warning lights related to charging system or electrical faults
• Test power windows, locks, and other electrical accessories for proper operation
• Perform window auto-up/down relearn procedure if necessary (consult owner's manual)
• Verify no unusual battery drain by checking voltage after 30 minutes (should be above 12.4V)
• Start vehicle and confirm charging system is functioning (battery voltage should be 13.5-14.5V with engine running)
• Reset clock and reprogram radio presets as needed

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