This procedure covers the removal and replacement of the negative battery cable on a 2023 Rivian EDV 500 electric delivery van, requiring high voltage system isolation and proper safety protocols.

Warnings

Tools required

Parts

• Negative battery cable × 1 — Use OEM specification
• Battery terminal hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow high voltage system to cool
3. Verify you have high voltage certification and proper PPE including insulated gloves rated for 1000V minimum
4. Photograph all cable routing and connections for reference during reinstallation
5. Disconnect the 12V auxiliary battery negative terminal to prevent accidental system activation
6. Access the Rivian service mode through the vehicle interface or diagnostic scanner to place the high voltage system in safe mode
7. Place high voltage lockout/tagout device on the high voltage disconnect location

Procedure

1. 1

   Access High Voltage Battery Compartment
   Remove the underbody protective panels to access the high voltage battery pack. The battery pack is located in the chassis floor. Remove fasteners securing the access panels using appropriate socket sizes. Set panels aside in a clean area.
2. 2

   Verify High Voltage System Isolation
   Using the high voltage multimeter, verify that no voltage is present at the high voltage disconnect point. Measurement should read 0V. If any voltage is detected, do not proceed and consult Rivian technical support. Wait an additional 5 minutes and retest if necessary.
3. 3

   Disconnect High Voltage Service Disconnect
   Locate the manual service disconnect (MSD) plug on the battery pack. While wearing high voltage gloves, rotate the service disconnect handle counterclockwise and pull straight out to remove. Store the MSD in a secure location away from the vehicle to prevent reconnection during service.
4. 4

   Identify Negative Battery Cable Routing
   Trace the negative battery cable from the battery pack to its grounding point on the vehicle chassis. The negative cable on the EDV 500 typically runs along the driver side of the battery pack and connects to a chassis ground point near the front motor assembly. Verify routing matches your reference photos.
5. 5

   Remove Cable Protective Covering
   Remove any protective conduit, heat shields, or cable management clips securing the negative cable along its route. Note the location of all clips and fasteners for reinstallation. Some sections may have integrated cable management that must be carefully separated.
6. 6

   Disconnect Negative Cable at Chassis Ground
   Locate the negative cable termination at the chassis ground point. Remove the fastener securing the cable lug to the grounding stud. Clean the grounding point with a wire brush to remove any corrosion. Inspect the grounding stud threads for damage.
7. 7

   Disconnect Cable at Battery Pack Terminal
   At the battery pack end, remove the fasteners securing the negative cable lug to the battery pack negative terminal. Support the cable weight to prevent strain on the connection while removing fasteners. Carefully lift the cable lug straight off the terminal post.
8. 8

   Remove Negative Battery Cable
   Carefully extract the negative battery cable from the vehicle, following the routing path documented earlier. Avoid pulling or dragging the cable across sharp edges or other components. Inspect the removed cable for any signs of damage, chafing, or heat degradation.
9. 9

   Prepare New Negative Cable
   Unpack the new negative battery cable and compare to the old cable to verify correct part. Check that all cable lugs are properly crimped and sealed. Apply a thin coat of dielectric grease to both cable lugs to prevent corrosion.
10. 10

    Route New Cable
    Route the new negative cable following the same path as the original cable. Ensure the cable does not contact sharp edges, moving parts, or heat sources. Temporarily secure the cable at several points to maintain proper routing during connection.
11. 11

    Connect Cable at Battery Pack
    Position the cable lug over the battery pack negative terminal post. Ensure clean metal-to-metal contact and proper seating. Install the terminal fastener and tighten per Rivian specifications. Since torque specs are not provided in database, follow torque values marked on the battery pack or in service manual. Do not overtighten as this can damage the terminal.
12. 12

    Connect Cable at Chassis Ground
    Position the cable lug over the chassis grounding stud. Ensure the grounding surface is clean and the lug seats fully against the chassis. Install and tighten the fastener securely. Verify the connection is tight and the cable lug cannot rotate.
13. 13

    Secure Cable and Install Protection
    Install all cable management clips, protective conduit, and heat shields in their original locations. Ensure the cable has slight slack to allow for vehicle movement but is not loose enough to vibrate or contact other components. Double-check that no part of the cable can contact sharp edges or moving parts.
14. 14

    Perform Isolation Resistance Test
    Before reinstalling the MSD, use the Rivian diagnostic scanner to perform a high voltage isolation resistance test. The system should show proper isolation values (typically >500 ohms/volt). If the test fails, recheck all connections and cable routing.
15. 15

    Reinstall High Voltage Service Disconnect
    With high voltage gloves still on, align the MSD plug and insert it fully into the receptacle. Rotate the handle clockwise until it locks into position. Verify the MSD is fully seated and locked.

Reassembly

1. Reinstall all underbody protective panels and tighten fasteners securely
2. Reconnect the 12V auxiliary battery negative terminal
3. Remove lockout/tagout device
4. Clear service mode through vehicle interface or diagnostic scanner
5. Perform system initialization procedure using Rivian diagnostic equipment

Verification

• Using diagnostic scanner, verify no high voltage system fault codes are present
• Verify battery management system recognizes proper voltage and all cell groups
• Perform a stationary high voltage system check - vehicle should be ready to drive with no warnings
• Test drive vehicle and verify normal operation of both electric motors
• Monitor vehicle for 24 hours for any new fault codes or charging issues
• Verify all vehicle systems that require initialization are functioning properly including regenerative braking

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