Chrysler 200 2015-2017 Electrical System Bolt Torque Specifications

Proper torque ensures a secure and reliable electrical connection. Under-tightening can lead to loose connections, increased resistance, overheating, and potential arcing. Over-tightening can damage components, strip threads, or distort terminals, leading to similar issues and future failures. Consistent torque prevents these problems, ensures the designed current flow, and improves overall safety and reliability of the electrical system.

Without a torque wrench, it's very difficult to consistently achieve the correct torque. You might overtighten, potentially damaging components like circuit boards or terminal blocks which are often made from brittle plastics. You might also undertighten, which can cause connections to loosen over time due to vibrations. This leads to poor electrical conductivity, increased resistance and heat generation, and possible intermittent electrical problems, such as lights flickering or components not functioning correctly.

Generally, it's not recommended to reuse electrical connection hardware, particularly self-locking nuts or bolts used on electrical grounds or power connections. Repeated use can reduce their clamping force, increasing resistance and heat generation. If reusing, ensure they are free of damage or corrosion, and use appropriate thread locking compounds if specified by the manufacturer. However, for optimal safety and reliability, it is best to replace them. This is especially true for higher amperage circuits.

If you strip a thread, stop immediately. Continuing will cause further damage. You may need to replace the component or repair the stripped thread using a thread repair kit (like Helicoil). If you are not confident with thread repair, consult a professional. Ignoring a stripped thread will lead to an insecure connection, possibly causing electrical problems and posing a safety risk. Avoid overtightening and apply consistent pressure when fastening.

Temperature can affect the materials used in electrical connections, including the bolts, washers, and terminals. Extreme temperatures, especially heat, may cause expansion or contraction which can alter the torque applied and can loosen or over-tighten the connection. While the listed specs are generally for ambient temperature, it's essential to be aware of the extremes in your environment, especially in the engine bay where temperatures can fluctuate significantly. If you are working in extreme temperatures, consider that some manufacturers provide torque adjustments for these scenarios.