This procedure covers the removal and replacement of the engine bay fuse box on a 2022 Rivian EDV 500 dual motor electric delivery vehicle.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box mounting hardware kit × 1 — Use OEM specification
• Electrical connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure vehicle has been off for at least 15 minutes to allow systems to power down
3. Verify high-voltage system is in safe state via instrument cluster display
4. Open and secure the front hood
5. Disconnect the 12V auxiliary battery negative terminal and wait 5 minutes for system discharge
6. Place fender covers to protect painted surfaces
7. Take photographs of all fuse box connections and wire routing from multiple angles

Procedure

1. 1

   Access the engine bay fuse box
   Locate the fuse box in the front compartment, typically mounted on the driver's side firewall area. Remove any plastic covers or protective shields covering the fuse box by releasing the retaining clips or fasteners.
2. 2

   Document fuse and relay positions
   Before removing any components, photograph the fuse box cover diagram and physically document which fuses and relays are installed in each position. Note any missing positions or non-standard fuse ratings. Remove the fuse box cover by releasing the locking tabs.
3. 3

   Remove all fuses and relays
   Using a fuse puller or needle-nose pliers, carefully remove all fuses and relays from the fuse box. Place them in labeled containers or on a diagram matching their original positions. Inspect each fuse for signs of failure or corrosion.
4. 4

   Disconnect primary power feed
   Locate the main power feed cable(s) entering the fuse box, typically heavy gauge cables with protective boots. Remove the protective boot and unbolt the cable terminal using the appropriate socket. These are typically high-amperage connections secured with 10mm or 13mm nuts.
5. 5

   Disconnect electrical connectors
   Working from top to bottom, disconnect all electrical connectors from the fuse box. Each connector will have a locking tab or slide lock that must be released before pulling. Apply even pressure and avoid pulling on wires. There are typically 4-8 multi-pin connectors on the EDV 500 fuse box.
6. 6

   Release wire harness routing clips
   Identify all wire harness routing clips and cable ties securing harnesses to the fuse box or nearby mounting points. Cut cable ties as necessary and release any push-pin style routing clips. Ensure adequate slack exists for fuse box removal.
7. 7

   Remove fuse box mounting fasteners
   Locate and remove all mounting bolts or fasteners securing the fuse box to the vehicle body. Rivian typically uses a combination of Torx and hex bolts. There are usually 3-4 mounting points. Support the fuse box with one hand while removing the final fastener.
8. 8

   Remove fuse box from vehicle
   Carefully lift the fuse box away from its mounting location while guiding wire harnesses clear. Watch for any hidden clips or connectors that may still be attached. Maneuver the fuse box out of the engine bay, being careful not to snag wires or damage surrounding components.
9. 9

   Prepare mounting location
   Clean the fuse box mounting surface on the firewall or body panel. Remove any corrosion, dirt, or old gasket material. Inspect mounting studs or threaded inserts for damage. Verify grounding points are clean and free of corrosion.
10. 10

    Install new fuse box
    Position the replacement fuse box into the mounting location, ensuring it is properly oriented and aligned with all connector access points. Start all mounting fasteners by hand before tightening to avoid cross-threading. Tighten mounting bolts in a cross-pattern to ensure even seating.
11. 11

    Reconnect electrical connectors
    Working from your reference photographs, reconnect each electrical connector to the fuse box. Each connector should click or lock into place securely. Verify each connector is fully seated and the locking mechanism is engaged. Apply dielectric grease to connector seals if specified.
12. 12

    Reconnect primary power feed
    Reconnect the main power feed cable(s) to the fuse box terminals. Ensure contact surfaces are clean and free of corrosion. Tighten cable terminal nuts firmly but do not overtighten. Reinstall protective boots over terminals.
13. 13

    Reinstall fuses and relays
    Using your documentation, reinstall all fuses and relays in their correct positions. Ensure each component is fully seated. Replace any blown fuses with the correct amperage rating as specified on the fuse box diagram. Do not install higher-rated fuses than specified.
14. 14

    Secure wire harnesses
    Reinstall all wire harness routing clips and install new cable ties to secure harnesses in their original routing paths. Ensure no wires are pinched, kinked, or in contact with sharp edges or hot surfaces. Maintain proper clearance from moving components.

Reassembly

1. Install the fuse box cover and ensure all locking tabs are engaged
2. Reinstall any protective shields or covers removed during disassembly
3. Reconnect the 12V auxiliary battery negative terminal
4. Remove fender covers and close the hood

Verification

• Turn the vehicle to accessory mode and verify the instrument cluster displays properly with no warning lights related to fuse box circuits
• Using a multimeter, verify voltage is present at key fuse locations as specified in service documentation
• Test operation of all electrical systems including lights, HVAC, power accessories, and charging systems
• Verify no loose fuses or relays by gently pressing on each component
• Check for proper operation of safety systems including airbag system (no warning lights)
• Perform a road test to verify all electrical systems function under normal driving conditions
• Scan for diagnostic trouble codes using Rivian diagnostic software and clear any codes related to battery disconnection

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