This procedure covers the removal and replacement of both positive and negative high-voltage battery cables on the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• High-voltage positive battery cable × 1 — Use OEM specification
• High-voltage negative battery cable × 1 — Use OEM specification
• High-voltage connector seals × 4 — Use OEM specification
• Cable retention clips × 6 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place safety cones around work area and post high-voltage warning signs
3. Verify Class C fire extinguisher is accessible
4. Ensure 12V battery is fully charged for system reinitialization after repair
5. Connect Rivian diagnostic scan tool and record any existing fault codes
6. Put on high-voltage insulated gloves and ensure they are rated and in good condition
7. Open all doors and windows for ventilation
8. Disable vehicle completely through diagnostic tool

Procedure

1. 1

   Disconnect 12V battery
   Locate the 12V auxiliary battery in the front compartment. Disconnect the negative terminal first, then the positive terminal. Isolate terminals to prevent accidental reconnection.
2. 2

   Access high-voltage battery compartment
   Remove the cargo area floor panels to access the battery pack. Remove the protective cover over the high-voltage junction box by removing the fasteners around the perimeter. Store fasteners in organized manner for reassembly.
3. 3

   Disable high-voltage system
   Locate the manual service disconnect (MSD) plug on top of the battery pack. Rotate the MSD counterclockwise and pull straight up to remove. Store the MSD in a secure location away from the vehicle. Lock out/tag out the MSD location.
4. 4

   Wait for capacitor discharge
   Wait minimum 15 minutes for all high-voltage capacitors to discharge completely. Do not touch any high-voltage components during this waiting period. Set a timer to ensure full discharge time.
5. 5

   Verify zero voltage
   Using high-voltage capable multimeter, verify 0 volts between positive and negative high-voltage terminals at the battery pack. Also verify 0 volts between each terminal and vehicle ground. Document voltage readings. Only proceed if readings are 0V.
6. 6

   Remove cable shields and routing clips
   Remove the protective orange shields covering the high-voltage cable connections. Release all cable retention clips along the routing path from battery pack to motor drive units. Note cable routing for reinstallation.
7. 7

   Disconnect positive cable at battery pack
   Remove the positive cable terminal fastener at the battery pack connection point. Carefully lift the terminal straight off to avoid damaging the connection point. Inspect terminal and connection point for signs of arcing or damage.
8. 8

   Disconnect positive cable at motor drive unit
   Locate the positive cable connection at the front motor drive unit. Remove the terminal fastener and carefully disconnect the cable. Support the cable weight during removal to prevent strain on connections.
9. 9

   Remove positive cable
   Following the noted routing path, carefully remove the positive high-voltage cable from the vehicle. Check all routing points to ensure cable is free before complete removal. Inspect cable along entire length for damage.
10. 10

    Disconnect and remove negative cable
    Repeat the disconnection process for the negative cable at both the battery pack and motor drive unit connections. Remove the cable following its routing path. Inspect all connection points and cable insulation for damage or wear.
11. 11

    Install new negative cable
    Route the new negative cable following the exact path of the original. Ensure cable does not contact sharp edges or moving components. Install all routing clips to secure cable properly. Apply dielectric grease to terminal connections before installation.
12. 12

    Connect negative cable terminals
    Connect negative cable terminal at battery pack first, ensuring proper seating and alignment. Install and tighten fastener to manufacturer specifications. Repeat at motor drive unit connection. Verify terminals are fully seated with no gaps.
13. 13

    Install new positive cable
    Route the new positive cable following the exact path of the original. Maintain proper separation from negative cable throughout routing. Install all routing clips. Apply dielectric grease to terminal connections before installation.
14. 14

    Connect positive cable terminals
    Connect positive cable terminal at battery pack, ensuring proper seating and alignment. Install and tighten fastener to manufacturer specifications. Repeat at motor drive unit connection. Double-check all connections are secure and properly aligned.
15. 15

    Reinstall shields and perform final checks
    Install new connector seals at all connection points. Reinstall the protective orange shields over all high-voltage connections. Verify all cable routing clips are installed and cables are properly secured. Check for adequate clearance from moving parts and sharp edges.

Reassembly

1. Reinstall the high-voltage junction box protective cover and secure all fasteners
2. Reinstall cargo area floor panels in reverse order of removal
3. Reconnect 12V battery, positive terminal first, then negative terminal
4. Remove lockout/tagout from MSD location
5. Reinstall the manual service disconnect (MSD) plug by inserting and rotating clockwise until it clicks
6. Ensure all tools and parts are removed from vehicle

Verification

• Connect Rivian diagnostic scan tool and clear any stored fault codes from the service procedure
• Perform high-voltage system integrity test using diagnostic tool
• Verify no high-voltage fault codes are present
• Perform insulation resistance test on high-voltage system (should show proper resistance values)
• Power on vehicle and verify ready-to-drive status is achieved
• Test drive vehicle to verify normal operation of both motor drive units
• Monitor for any warning lights or messages on instrument cluster
• Verify regenerative braking functions normally
• Perform final scan for fault codes after test drive

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