High Voltage Wiring Harness

Replace or repair the high voltage wiring harness that connects the battery pack to motor controllers and charging system on the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• High voltage wiring harness assembly × 1 — Use OEM specification - Rivian part number required
• High voltage connector seals/boots × 1 — Use OEM specification
• Cable mounting clips and brackets × 1 — Use OEM specification
• High voltage warning labels × 1 — Use OEM specification

Preparation

1. Ensure vehicle has been powered off for at least 15 minutes before beginning work
2. Park vehicle on level ground in a well-ventilated area away from flammable materials
3. Engage parking brake and place wheel chocks at all four wheels
4. Put on Class 0 insulated electrical gloves and verify they are undamaged and within test date
5. Remove driver floor mat and locate 12V battery disconnect under driver seat or in rear cargo area per service manual
6. Disconnect 12V low voltage battery negative terminal and wait 5 minutes for systems to power down
7. Install lockout/tagout device on 12V battery to prevent reconnection
8. Access high voltage service disconnect (typically under vehicle or in battery enclosure) per manufacturer procedure
9. Remove high voltage service disconnect plug and store in your pocket to prevent unauthorized reconnection
10. Wait minimum 15 minutes for high voltage system capacitor discharge
11. Place high voltage warning signs on vehicle exterior
12. Have fire extinguisher readily accessible

Procedure

1. 1

   Verify system de-energization
   Using CAT III rated multimeter with proper high voltage test leads, verify zero voltage at high voltage junction box terminals. Test between positive and negative high voltage terminals, then test each terminal to vehicle chassis ground. All readings must be below 5V DC. If voltage is present, wait additional 15 minutes and retest. Document all voltage readings.
2. 2

   Remove interior trim panels
   Remove cargo area side trim panels and floor covering to access high voltage cable routing. Use plastic pry tools to release trim clips without damage. On EDV 500, cables typically route along driver side from battery to front motor controller and passenger side to rear motor controller. Remove center tunnel cover if equipped to access charging system connections.
3. 3

   Document existing harness routing
   Before removal, photograph and document exact routing of high voltage cables including all mounting points, separation distances from low voltage wiring, and positions of cable securing clips. Note orientation of all connectors and any identification markings. This documentation is critical for proper reinstallation.
4. 4

   Disconnect charging port connections
   Locate charging port connection to high voltage harness near front of vehicle. Using appropriate cable disconnection tool, release locking mechanism on orange high voltage connector. Pull connector straight back without twisting. Inspect connector pins and seals for damage. Cover exposed connector ends with insulating caps.
5. 5

   Disconnect front motor controller connections
   Access front motor controller under vehicle or through front service access. The controller will have multiple orange high voltage connectors. Release each connector locking tab using proper technique - typically requires sliding outer sleeve while pulling connector. Mark each connection position if not keyed differently. Verify no voltage present before handling.
6. 6

   Disconnect rear motor controller connections
   Access rear motor controller connections following same procedure as front controller. EDV 500 uses dual motor AWD configuration so both controllers must be disconnected. Support weight of cables during removal to prevent stress on connectors.
7. 7

   Disconnect battery pack connections
   Access high voltage connections at battery pack junction box. These are the main power connections and will be the largest gauge cables. Release locking mechanisms on battery positive and negative connections. These connectors may require significant force to separate - pull straight without twisting. Some connections may require specific tool angles for access.
8. 8

   Release cable securing points
   Working methodically from battery toward motor controllers, release all cable mounting clips, P-clips, and cable tie anchors. Note that high voltage cables must maintain minimum separation distances from chassis and other components. Keep track of all mounting hardware and their positions.
9. 9

   Remove high voltage harness
   Carefully remove entire high voltage harness assembly from vehicle. The harness is heavy due to cable gauge - may require two people. Avoid dragging cables across sharp edges. Inspect all mounting points in vehicle for damage or debris before installing new harness.
10. 10

    Prepare new harness and verify compatibility
    Unpack new high voltage harness and verify part number matches vehicle specification. Inspect all connectors for damage, proper sealing boots, and presence of dielectric grease. Check cable jacket for any damage from shipping. Compare new harness layout to documented routing of old harness.
11. 11

    Install new harness
    Route new high voltage harness following exact path documented during removal. Maintain proper separation distances from low voltage wiring, moving components, and hot surfaces. Install mounting clips and brackets in exact original positions. Ensure cables are not kinked, twisted, or under tension. The harness should have natural curves and adequate service loop at connections.
12. 12

    Connect battery pack terminals
    Begin reconnection at battery pack. Clean mating surfaces of connectors with electrical contact cleaner. Apply thin layer of dielectric grease to connection surfaces if specified by manufacturer. Align connectors carefully and push together until locking mechanism fully engages with audible click. Verify mechanical lock is secure by attempting to pull connector apart.
13. 13

    Connect motor controller terminals
    Connect high voltage cables to front and rear motor controllers in documented positions. Ensure each connector seats fully and locks properly. Double-check that no pins are bent or misaligned. Orange safety locks must be fully engaged on all connections.
14. 14

    Connect charging system terminals
    Reconnect charging port high voltage connections. Verify proper seating and locking. Ensure charging port connector seals are properly positioned to maintain weatherproofing.
15. 15

    Secure and verify installation
    Install all cable securing clips, ties, and brackets. Verify minimum clearances are maintained throughout cable routing - typically 25mm from chassis and 50mm from moving parts, but confirm with service specifications. Inspect entire harness installation for proper routing, secure mounting, and absence of stress points. Replace any high voltage warning labels that were damaged during removal.

Reassembly

1. Reinstall all interior trim panels and floor covering using new clips where originals were damaged
2. Perform visual inspection of entire high voltage system - all connections must show orange locking indicators fully engaged
3. Before reinstalling high voltage service disconnect, perform insulation resistance test per manufacturer procedure (typically 500V megger test showing >500 megohms)
4. Reinstall high voltage service disconnect plug ensuring proper orientation and full engagement
5. Remove lockout/tagout device from 12V battery and reconnect 12V negative terminal
6. Connect Rivian diagnostic software to vehicle

Verification

• Use diagnostic software to clear any stored high voltage system fault codes from the de-energization procedure
• Perform high voltage system integrity test using manufacturer diagnostic procedures - this typically includes insulation resistance verification and connection integrity checks
• Monitor for any new fault codes related to high voltage system, motor controllers, or charging system
• With vehicle still in service mode, observe diagnostic data for proper voltage readings at battery pack, motor controllers, and charging system (should show nominal pack voltage ~400V)
• Perform controlled power-up sequence per manufacturer procedure, monitoring for any arcing, unusual sounds, or fault codes
• Test vehicle in limited operation mode first - verify both motors engage properly and no high voltage warnings appear
• Perform test drive in safe area monitoring for proper operation of both drive motors, regenerative braking, and absence of high voltage system warnings
• Verify charging system operates correctly by connecting to charger and confirming proper communication and charge initiation
• Perform final diagnostic scan and verify no high voltage system fault codes present
• Document all test results and repair details including harness part number and installation date

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