Battery Cable - Positive

This procedure covers the replacement of the positive battery cable on the 2023 Rivian EDV 500, including safe disconnection of the high-voltage battery system and removal/installation of the positive cable assembly.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• Cable retention clips × 1 — Use OEM specification
• High-voltage warning labels × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is powered off and key fob is at least 20 feet away from vehicle
3. Put on high-voltage insulated gloves and safety equipment
4. Photograph cable routing and connections for reference during reinstallation
5. Access battery compartment by removing underbody shield panels
6. Verify all personnel are clear of the vehicle before beginning HV disconnect procedure

Procedure

1. 1

   Disable high-voltage system
   Connect Rivian diagnostic scan tool and navigate to the HV battery service menu. Select 'HV System Service Mode' to place the battery management system into safe mode. Wait for confirmation that the service disconnect has been electronically opened and all contactors are open. Verify system status shows 'HV System Disabled'.
   ⚠️Do not proceed until scan tool confirms HV system is fully disabled and contactors are open.
2. 2

   Perform manual service disconnect
   Locate the manual service disconnect (MSD) plug on the high-voltage battery pack. Using insulated tools, rotate the MSD counterclockwise to unlock, then pull straight out to remove. Place MSD in a secure location away from the vehicle. Install the supplied safety lockout cap over the MSD receptacle.
   ⚠️The manual service disconnect must be removed and stored safely to prevent accidental reconnection during service.
3. 3

   Wait for capacitor discharge
   After removing the MSD, wait a minimum of 10 minutes to allow high-voltage capacitors in the drive units and charging system to fully discharge. Use a calibrated high-voltage multimeter to verify voltage is below 5V DC at the positive cable connection point before proceeding.
   ⚠️Residual voltage can remain in capacitors even after disconnect. Never skip the discharge waiting period.
4. 4

   Disconnect 12V auxiliary battery
   Locate the 12V auxiliary battery in the front compartment. Disconnect the negative terminal first, then the positive terminal. Secure cables away from battery posts to prevent accidental reconnection during HV service.
   ⚠Disconnecting 12V battery will erase certain vehicle settings and may require recalibration procedures after reconnection.
5. 5

   Remove cable shields and covers
   Remove the orange high-voltage cable protective covers from the positive cable assembly. Remove all cable retention clips and cable routing brackets along the cable path. Note the position of each mounting point for proper reinstallation.
   ℹ️Orange covers and cables indicate high-voltage components. Handle with insulated gloves even when system is disabled.
6. 6

   Disconnect positive cable from battery pack
   Locate the positive cable connection at the high-voltage battery pack. Remove the terminal fastener (typically a hex bolt) securing the cable lug to the battery positive terminal. Carefully lift the cable lug straight off the terminal post. Inspect terminal for any signs of arcing, corrosion, or damage.
   ⚠Do not pry or twist the cable lug during removal as this can damage the battery terminal or connection point.
7. 7

   Disconnect positive cable from PDU
   Trace the positive cable to the Power Distribution Unit (PDU) located in the front compartment. Remove the mounting fastener securing the cable to the PDU input terminal. Carefully separate the cable connection and cover the exposed PDU terminal with electrical tape to prevent contamination.
8. 8

   Remove cable routing fasteners
   Working from the battery pack toward the front of the vehicle, remove all remaining cable routing clips, brackets, and fasteners along the cable path. Note that some fasteners may also secure coolant lines or other cables. Support the cable assembly as you release each mounting point to prevent it from dropping onto other components.
9. 9

   Extract positive cable assembly
   Carefully remove the entire positive cable assembly from the vehicle, following the documented routing path. Feed the cable through any pass-through grommets in the battery pack enclosure and body panels. Inspect all grommets for damage and replace if necessary.
   ⚠The cable assembly is heavy and may have sharp edges. Use proper lifting technique and handle carefully.
10. 10

    Prepare new cable assembly
    Remove the new positive cable assembly from packaging and inspect for any shipping damage. Compare the new cable with the old cable to verify correct part number and routing configuration. Clean all terminal surfaces with electrical contact cleaner and apply a thin coat of dielectric grease to connection points.
11. 11

    Install new cable assembly
    Route the new positive cable assembly through the vehicle following the exact path documented during removal. Ensure the cable passes through all grommets and does not contact sharp edges or moving components. Feed the cable from the PDU location back to the battery pack, maintaining proper clearance from coolant lines and other systems.
    ⚠Improper cable routing can result in cable damage, coolant line interference, or electromagnetic interference with vehicle systems.
12. 12

    Connect cable to battery pack
    Position the cable lug onto the battery pack positive terminal. Ensure the lug is fully seated and properly aligned before installing the fastener. Install the terminal fastener and tighten according to manufacturer specifications (torque specification not available in database - refer to service manual). Verify the connection is secure with no movement.
13. 13

    Connect cable to PDU
    Remove the protective tape from the PDU terminal. Position the cable lug onto the PDU input terminal, ensuring proper alignment and full seating. Install and tighten the mounting fastener according to manufacturer specifications (torque specification not available in database - refer to service manual).
14. 14

    Install cable routing hardware
    Working from the battery pack to the PDU, install all cable routing clips, brackets, and fasteners in their original positions. Ensure the cable has no excessive tension or loose sections. Verify minimum clearance requirements are met between the cable and all moving or hot components. Install all protective orange covers over the cable assembly.
15. 15

    Reconnect 12V battery and HV system
    Reconnect the 12V auxiliary battery, connecting positive terminal first, then negative. Remove the lockout cap from the MSD receptacle and reinstall the MSD plug, pushing straight in until seated and rotating clockwise to lock. Connect the diagnostic scan tool and exit HV Service Mode to re-enable the high-voltage system. Verify system status shows 'HV System Active'.
    ⚠Ensure all tools and equipment are clear of the HV system before re-enabling.

Reassembly

1. Verify all cable connections are tight and properly torqued per service manual specifications
2. Ensure all protective orange covers are installed over high-voltage components
3. Verify cable routing matches original configuration with proper clearances
4. Install all underbody shields and panels removed during access
5. Apply new high-voltage warning labels if any were damaged during service

Verification

• Use diagnostic scan tool to verify no HV system fault codes are present
• Verify battery management system reports proper voltage and all contactors are functioning
• Check that vehicle powers on normally and displays no warning messages
• Perform a low-speed test drive to verify normal operation of both drive motors
• Monitor battery temperature and charging system for first 24 hours of operation
• Verify positive cable shows no signs of heating or discoloration at connection points after initial operation

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