High Voltage Cable Inspection

Visual and physical inspection of all high voltage cables, connections, and protective shielding in the dual motor AWD electric drivetrain to ensure safe operation and prevent electrical hazards.

Warnings

Tools required

Parts

• HV cable protective shielding (if damaged) × 1 — Use OEM specification
• HV cable routing clips (if damaged) × 5 — Use OEM specification
• HV connection sealing caps (if damaged) × 4 — Use OEM specification
• Cable ties (heavy duty) × 10 — Use OEM specification
• Dielectric grease × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in a dry, well-lit work area with adequate ventilation
2. Ensure vehicle is in Park and apply parking brake
3. Place wheel chocks at all four wheels
4. Turn off vehicle completely and remove key fob from vehicle interior
5. Connect Rivian diagnostic tool and verify no active high voltage system faults
6. Open charge port door and verify vehicle is not connected to charging equipment
7. Allow vehicle to sit for at least 30 minutes after last use to allow components to cool
8. Gather all required personal protective equipment including insulated gloves and safety glasses
9. Review Rivian service documentation for specific high voltage component locations on EDV 500
10. Prepare lockout/tagout tags and document start time of procedure

Procedure

1. 1

   Disable high voltage system
   Open the front hood and locate the high voltage service disconnect. Remove the service disconnect cover by releasing the two clips. Pull the orange service disconnect handle straight up to disconnect the high voltage system. Install the lockout/tagout device to prevent reconnection. Verify the HV system indicator light (if equipped) is off on the instrument cluster.
2. 2

   Verify system de-energization
   Wait a minimum of 10 minutes for high voltage capacitors to discharge. Using a high voltage rated multimeter, verify zero voltage across the main high voltage bus bars at the service disconnect location. Check voltage at multiple points along accessible HV terminals. Document voltage readings as zero before proceeding. DO NOT proceed if any voltage is detected.
3. 3

   Remove underbody protective panels
   Lift vehicle on appropriate lift or support safely on jack stands rated for vehicle weight. Remove front and rear underbody protective panels to access high voltage cables running between battery pack, front motor, and rear motor. Remove approximately 15-20 fasteners depending on configuration. Set panels aside in clean area.
4. 4

   Inspect battery pack to front motor HV cables
   Locate the orange high voltage cables running from the battery pack forward to the front drive unit. Visually inspect the entire length of cables for any signs of: abrasion, cuts, melting, discoloration, cracking, or deformation of the orange insulation jacket. Check for evidence of contact with sharp edges, heat sources, or moving components. Inspect cable routing clips and ensure cables are properly secured every 12-18 inches. Check for adequate clearance (minimum 25mm) from suspension components, drivetrain parts, and body structure.
5. 5

   Inspect battery pack to rear motor HV cables
   Locate the orange high voltage cables running from the battery pack rearward to the rear drive unit. Perform the same comprehensive visual inspection as front cables: check insulation integrity, routing security, clearances, and protection from environmental hazards. Pay special attention to areas where cables pass through bulkheads or mounting points. Verify protective grommets are intact and properly seated.
6. 6

   Inspect HV cable connectors and terminations
   Inspect all high voltage connectors at: battery pack terminals, front motor terminals, rear motor terminals, and any junction boxes. Check connector housings for cracks, damage, or signs of arcing (black marks, melting). Verify all connector locking mechanisms are engaged and safety clips are in place. Check connector seals and boots for deterioration or moisture intrusion. Do NOT disconnect connectors unless damage is found requiring replacement.
7. 7

   Inspect HV cable shielding and protective covers
   Examine all orange protective shielding covering high voltage cables throughout the vehicle. Check for missing sections, loose mounting points, cracks, or damage that would expose underlying cables. Verify all shielding fasteners are present and secure. Inspect conduit where cables transition through floor pan or frame sections. Ensure all protective boots at motor housings are properly sealed.
8. 8

   Check for contamination and foreign material
   Inspect around all high voltage cables and components for presence of: fluid leaks (coolant, brake fluid), road debris, corrosion, or chemical contamination. Check battery pack area for any signs of moisture accumulation. Verify drain holes in protective covers are clear. Remove any foreign material found near HV components using appropriate tools while wearing insulated gloves.
9. 9

   Perform insulation resistance test
   Using an insulation resistance tester (megohmmeter), test insulation resistance between HV positive and vehicle ground, and HV negative and vehicle ground at multiple accessible test points. Readings should be greater than 500 ohms per volt of system voltage (minimum 400k ohms for 800V system). Document all readings. Any reading below specification indicates insulation breakdown requiring immediate cable replacement.
10. 10

    Inspect cooling system integration
    Check high voltage components that interface with the cooling system including motor cooling lines and battery thermal management connections. Verify no coolant leaks are present near any HV connectors or cables. Inspect cooling hoses for proper routing away from HV cables with adequate clearance. Check coolant level in reservoir is within proper range.
11. 11

    Document findings and address issues
    Photograph any damage, wear, or concerns found during inspection. Measure and record any insulation damage depth or cable abrasion. If any high voltage cable shows insulation damage exposing conductors, the cable MUST be replaced - do not proceed with reassembly. Replace any damaged routing clips, protective shielding, or hardware. Apply dielectric grease to connector seals if specified by manufacturer.
12. 12

    Re-enable high voltage system
    Reinstall all underbody protective panels ensuring proper alignment and torque on all fasteners. Remove lockout/tagout device from service disconnect. Reinstall the high voltage service disconnect by aligning the connector and pushing firmly until it clicks into place. Reinstall the service disconnect cover. Connect diagnostic tool and clear any stored fault codes related to service disconnect removal.
13. 13

    Perform system verification
    With diagnostic tool connected, power on the vehicle to Ready mode. Monitor for any high voltage system fault codes. Verify HV system voltage reads nominal (approximately 750-820V for full battery). Check that both front and rear motors show ready status. Verify no insulation resistance faults are present. Allow vehicle to remain in Ready mode for 5 minutes while monitoring for any warnings.

Reassembly

1. Ensure all underbody panels are properly secured with all fasteners tightened
2. Verify no tools or equipment remain under vehicle or in battery compartment areas
3. Confirm service disconnect is fully seated and locked in place
4. Double-check all HV cable routing clips and protective shielding are secure
5. Remove wheel chocks and lower vehicle from lift if elevated

Verification

• Vehicle powers on to Ready mode without any high voltage system warnings or fault codes
• Diagnostic scan shows no insulation resistance faults or HV system errors
• All high voltage components show nominal operating voltage on diagnostic tool
• Test drive vehicle at low speed in safe area to verify both motors engage properly
• Re-scan for fault codes after test drive - no new codes should be present
• Visual re-inspection shows no HV cables contacting moving parts or showing stress
• Document completion of inspection with date, findings, and any parts replaced in maintenance log

Related trouble codes on this vehicle

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