This procedure covers the inspection, cleaning, and replacement of the high-voltage battery terminals on the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Battery terminal connectors (if corroded) × 1 — Use OEM specification
• Terminal bolts and hardware (if damaged) × 1 — Use OEM specification
• High-voltage cable insulation tape × 1 — Use OEM specification
• Cable ties × 5 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure vehicle is powered off completely and key fob is at least 15 feet away from vehicle
3. Verify 12V auxiliary battery is fully charged before beginning work
4. Place high-voltage warning signs around the vehicle to alert others
5. Review Rivian high-voltage safety procedures and emergency response protocols
6. Have fire extinguisher rated for electrical fires readily available
7. Document any diagnostic trouble codes (DTCs) before beginning work

Procedure

1. 1

   Disable high-voltage system
   Access the vehicle service menu through the center display. Navigate to Service Mode and select 'Disable High-Voltage System'. Confirm the system has been disabled and verify the high-voltage indicator light is off on the instrument cluster. Apply lockout/tagout procedures per Rivian service manual.
2. 2

   Disconnect 12V auxiliary battery
   Locate the 12V auxiliary battery in the front compartment. Disconnect the negative terminal first, then the positive terminal. Isolate both cables to prevent accidental reconnection. Wait at least 2 minutes for vehicle systems to fully power down.
3. 3

   Remove underbody access panels
   Using the trim removal tools, carefully remove the underbody panels to access the high-voltage battery pack. Remove all fasteners and store them in an organized manner. The battery terminal access is typically located on the driver side of the battery pack.
4. 4

   Remove high-voltage service disconnect
   Locate the high-voltage service disconnect plug on the battery pack. Remove the orange safety cover by pressing the release tabs. Rotate the disconnect handle counterclockwise and pull firmly to remove the service plug. Store the plug in your tool box to maintain lockout.
5. 5

   Wait for capacitor discharge
   Wait a minimum of 10 minutes after removing the service disconnect to allow all high-voltage capacitors to fully discharge. Do not proceed until the full waiting period has elapsed. This is critical for technician safety.
6. 6

   Verify zero voltage
   Put on high-voltage safety gloves. Using the high-voltage capable multimeter with insulated probes, verify zero voltage between the positive and negative battery terminals, and between each terminal and vehicle ground. Do not proceed if any voltage is detected.
7. 7

   Remove terminal covers and insulators
   Carefully remove the orange safety covers from the high-voltage battery terminals. Remove any additional insulation blankets or protective covers. Note the routing and position of all wiring and insulators for proper reassembly.
8. 8

   Disconnect negative terminal
   Using insulated tools and wearing high-voltage gloves, loosen the negative terminal bolt. Remove the bolt completely and carefully lift the cable terminal away from the battery post. Wrap the exposed terminal end with high-voltage insulation tape to prevent accidental contact.
9. 9

   Disconnect positive terminal
   Using insulated tools, loosen and remove the positive terminal bolt. Carefully lift the cable terminal away from the battery post. Immediately wrap the exposed terminal end with high-voltage insulation tape. Keep the positive terminal separated from the negative terminal and any grounded surfaces.
10. 10

    Inspect and clean terminals
    Inspect both battery posts and cable terminals for corrosion, damage, or overheating signs (discoloration, melting). Clean the battery posts and cable terminals with the battery terminal cleaner brush. If corrosion is severe or terminals are damaged, replace affected components. Ensure all contact surfaces are clean and bright.
11. 11

    Reconnect positive terminal
    Remove insulation tape from positive terminal. Apply a thin coat of dielectric grease to the battery post and cable terminal contact surfaces. Position the positive cable terminal onto the battery post, ensuring full contact. Install the terminal bolt and tighten to manufacturer specifications using the torque wrench. Verify the connection is secure with no movement.
12. 12

    Reconnect negative terminal
    Remove insulation tape from negative terminal. Apply dielectric grease to contact surfaces. Position the negative cable terminal onto the battery post with full contact. Install the terminal bolt and tighten to manufacturer specifications. Verify secure connection with no movement.
13. 13

    Reinstall terminal covers and insulators
    Reinstall all insulation blankets and protective covers in their original positions. Install the orange safety covers over both terminals, ensuring they are fully seated and locked. Verify all high-voltage components are properly insulated and there are no exposed conductive surfaces.
14. 14

    Reinstall service disconnect
    Insert the high-voltage service disconnect plug into its receptacle. Rotate the handle clockwise until it locks into position. Install the orange safety cover over the disconnect. Verify the disconnect is fully seated and secure.

Reassembly

1. Reinstall all underbody access panels and secure all fasteners
2. Reconnect the 12V auxiliary battery, positive terminal first, then negative terminal
3. Remove lockout/tagout devices and warning signs
4. Clear Service Mode through the vehicle center display
5. Verify all panels and covers are properly secured before operating vehicle

Verification

• Power on the vehicle and verify the high-voltage system initializes without error codes
• Check for any high-voltage system warning lights or messages on the instrument cluster
• Use Rivian diagnostic software to scan for any battery-related DTCs
• Verify battery voltage readings are normal and balanced (typically 350-400V at rest)
• Perform a brief test drive and monitor battery system performance
• Re-inspect terminal connections after test drive to ensure no looseness or overheating
• Document all work performed and any parts replaced in the vehicle service records

More procedures for this vehicle