electrical

Battery Cable - Positive

for 2022 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Advanced

Time

2.0 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure involves safely disconnecting and replacing the positive battery cable on a 2022 Rivian EDV 500 electric delivery van, requiring isolation of the high-voltage system and removal of protective covers.

Warnings

⚠️This vehicle contains high-voltage systems exceeding 400V DC. Improper handling can result in severe injury or death. Only qualified EV technicians should perform this procedure.

⚠️Always verify the high-voltage system is fully de-energized using a multimeter before touching any cables or connections.

⚠️The battery pack may retain voltage even after isolation. Wait minimum 5 minutes after disconnecting service disconnect before proceeding.

⚠Never work on the high-voltage system in wet conditions or with wet gloves.

⚠Disconnecting the battery will erase stored fault codes and require system reinitialization.

Tools required

Electrically insulated gloves rated for EV work (Class 0 minimum, 1000V)Essential

High-voltage safety lockout deviceEssential

Multimeter with high-voltage capabilityEssential

Socket set (metric)Essential

Torque wrenchEssential

Trim removal tool set

Battery terminal puller

Wire brush

Dielectric grease

Parts

Positive battery cable assembly × 1 — Use OEM specification
Battery terminal protective boot × 1 — Use OEM specification
Cable mounting hardware × 1 — Use OEM specification

Preparation

Park vehicle on level ground and apply parking brake
Ensure vehicle is powered off completely and key fob is at least 15 feet away
Put on electrically insulated gloves rated for high-voltage work
Disconnect the 12V auxiliary battery negative terminal first, then positive terminal
Wait 2 minutes for vehicle systems to fully power down
Place high-voltage warning signs around the work area
Review Rivian service documentation for specific safety protocols

Procedure

1
Access the high-voltage battery compartment
Remove the lower belly pan or access panel beneath the vehicle to expose the high-voltage battery pack. This may require removing multiple fasteners. Support the panel carefully as it may be large and heavy on the EDV 500.
2
Locate and access the service disconnect
Identify the high-voltage service disconnect located on the battery pack assembly. Remove the protective cover by releasing the locking tabs or fasteners. The service disconnect is typically orange-colored for visibility.
3
Remove the service disconnect
Pull the service disconnect handle or lever to physically disconnect the high-voltage system. Install the high-voltage safety lockout device to prevent accidental reconnection. Secure the disconnect in a safe location away from the vehicle.
4
Wait for capacitor discharge
Wait a minimum of 5 minutes to allow all high-voltage capacitors in the system to fully discharge. This is critical for safety. Do not skip or shorten this waiting period.
5
Verify system de-energization
Using a high-voltage capable multimeter, verify that voltage at the positive battery cable terminal is 0V DC. Test between the positive terminal and vehicle ground, and between positive and negative terminals. Record readings for documentation.
6
Remove protective covers and guards
Remove any additional protective covers, cable guards, or heat shields covering the positive battery cable routing. Note the position and orientation of all components for reinstallation.
7
Document cable routing
Take photographs or make detailed notes of the positive cable routing, including all mounting points, clips, and how it interfaces with other components. This is essential for proper reinstallation.
8
Disconnect positive cable at load end
Locate where the positive cable connects to the power distribution unit or motor controller. Remove the fastening bolt or nut securing the cable terminal. Carefully lift the terminal away from the connection point.
9
Release cable mounting points
Work along the cable route and release all cable clips, brackets, and mounting points securing the positive cable. Support the cable weight as you release each mounting point to prevent strain on remaining connections.
10
Disconnect positive cable at battery pack
Remove the bolt or fastener securing the positive cable terminal to the battery pack main positive terminal. Use a battery terminal puller if necessary to avoid damaging the terminal. Remove the cable completely from the vehicle.
11
Inspect and clean connection points
Inspect the battery pack positive terminal and the load-end connection point for corrosion, damage, or overheating signs. Clean terminals with a wire brush if needed. Replace any damaged components.
12
Install new positive cable at battery pack
Position the new positive cable terminal onto the battery pack main positive terminal. Ensure the terminal is fully seated and properly oriented. Install and hand-tighten the securing fastener. Note: Torque specifications not available in database - consult Rivian service manual for proper torque value.
13
Route new cable and secure mounting points
Route the new positive cable following the exact path documented in step 7. Install all cable clips, brackets, and mounting points to secure the cable. Ensure the cable has no kinks, sharp bends, or contact with sharp edges.
14
Connect positive cable at load end
Position the positive cable terminal onto the power distribution unit or motor controller connection point. Ensure proper orientation and full seating. Install and hand-tighten the securing fastener. Note: Torque specifications not available in database - consult Rivian service manual for proper torque value.
15
Apply protective coating and reinstall covers
Apply a thin layer of dielectric grease to all exposed terminals for corrosion protection. Install the protective boot over the positive terminal. Reinstall all cable guards, heat shields, and protective covers in reverse order of removal.

Reassembly

Reinstall the service disconnect into its receptacle, ensuring it is fully seated and locked in place
Remove the safety lockout device
Reinstall the service disconnect protective cover
Reinstall the belly pan or access panel with all fasteners properly secured
Reconnect the 12V auxiliary battery, connecting positive terminal first, then negative terminal
Verify all tools and parts have been removed from the work area

Verification

Perform a visual inspection to confirm all cables are properly routed and secured with no loose components
Verify all protective covers and guards are installed correctly
Power on the vehicle and check for any warning lights or error messages related to the high-voltage system
Use Rivian diagnostic software to scan for fault codes and verify high-voltage system integrity
Confirm proper vehicle operation by running self-diagnostics and verifying ready-to-drive status
Test drive the vehicle briefly to ensure normal operation and monitor for any unusual behavior or warning messages

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