This procedure covers the removal and replacement of both positive and negative high-voltage battery cables on the 2023 Rivian EDV 500, including proper disconnect and reconnection procedures for the dual motor AWD electric drive system.

Warnings

Tools required

Parts

• High-voltage positive battery cable assembly × 1 — Use OEM specification
• High-voltage negative battery cable assembly × 1 — Use OEM specification
• HV connector seals/gaskets × 4 — Use OEM specification
• Cable mounting hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place safety cones around vehicle and post high-voltage work warning signs
3. Ensure vehicle is in Park mode and powered completely off
4. Verify battery state of charge is below 80% for safety (recommended)
5. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
6. Put on appropriate personal protective equipment including insulated gloves and face shield
7. Remove rear cargo area floor panels to access high-voltage battery compartment
8. Document all cable routing and connector orientations with photos before disassembly

Procedure

1. 1

   Access high-voltage service disconnect
   Locate the high-voltage service disconnect plug in the rear battery compartment beneath the access cover. Remove the protective cover by turning counterclockwise. The disconnect is typically orange-colored and located on the driver's side of the battery pack.
2. 2

   De-energize high-voltage system
   Pull the high-voltage service disconnect straight out from its socket with a firm, steady motion. Store the disconnect plug in your pocket or a secure location to prevent accidental reconnection. Install the lockout device if available. Wait a minimum of 15 minutes for high-voltage system capacitors to fully discharge.
3. 3

   Verify system is de-energized
   Using a calibrated high-voltage multimeter, verify zero voltage across the main positive and negative HV terminals at the battery pack. Test between positive and negative, positive and chassis ground, and negative and chassis ground. All readings must be less than 10V DC. Do not proceed if voltage is present.
4. 4

   Remove underbody protective covers
   Remove the underbody skid plates and protective covers to access the battery cable routing paths. The cables run from the battery pack forward to both front and rear motor drive units. Remove all fasteners securing the protective covers and set aside in organized manner for reinstallation.
5. 5

   Disconnect positive cable at front motor
   Locate the positive cable connection at the front motor drive unit. Remove the orange protective cover from the connector. Using the appropriate cable disconnect tool, release the locking mechanism and carefully separate the connector. Support the cable weight to prevent strain on connected components. Cap the exposed connector immediately with protective covers.
6. 6

   Disconnect positive cable at rear motor
   Locate the positive cable connection at the rear motor drive unit. Remove the protective cover and use the cable disconnect tool to release the locking tab. Separate the connector while supporting cable weight. Install protective caps on exposed terminals.
7. 7

   Disconnect positive cable at battery pack
   At the high-voltage battery pack, locate the main positive terminal connection. Remove the protective cover and any secondary retention hardware. Using proper socket, loosen and remove the main terminal bolt. Carefully lift the positive cable lug from the terminal post while supporting the cable assembly. Inspect terminal and cable lug for corrosion or damage.
8. 8

   Remove positive cable assembly
   Release all cable retaining clips and brackets along the cable routing path from battery pack to both motors. Carefully route the positive cable assembly out of the vehicle, noting any grommets or protective sleeves. Take care not to drag cable across sharp edges. Set cable aside in clean work area.
9. 9

   Disconnect negative cable at front motor
   Locate the negative cable connection at the front motor drive unit. Remove the protective cover and release the locking mechanism using the disconnect tool. Separate the connector while supporting the cable. Install protective caps on exposed terminals.
10. 10

    Disconnect negative cable at rear motor
    Access the negative cable connection at the rear motor drive unit. Remove protective cover, release locking mechanism, and separate the connector while supporting cable weight. Cap all exposed high-voltage terminals immediately.
11. 11

    Disconnect negative cable at battery pack
    At the battery pack negative terminal, remove protective cover and retention hardware. Loosen and remove the main terminal bolt. Lift the negative cable lug from the terminal post while supporting the cable assembly. Clean terminal surfaces with wire brush if corrosion is present.
12. 12

    Remove negative cable assembly
    Release all retaining clips and mounting brackets securing the negative cable along its routing path. Carefully remove the negative cable assembly from the vehicle, preserving all grommets and protective components. Inspect the entire cable path for any damage or wear to adjacent components.
13. 13

    Install new negative cable assembly
    Route the new negative cable assembly through the vehicle following the same path as the original. Install all grommets and protective sleeves in their correct positions. Secure cable with all retaining clips and brackets, ensuring proper clearance from moving parts and heat sources. Do not overtighten clips that could damage cable insulation.
14. 14

    Connect negative cable to battery pack
    Position the negative cable lug onto the battery pack negative terminal. Ensure the mating surfaces are clean and free of corrosion. Apply a thin coat of dielectric grease to the terminal surfaces. Install and hand-tighten the terminal bolt, then torque to specification per service manual. Install new terminal seal if equipped. Install protective cover.
15. 15

    Connect negative cable to motors
    At both rear and front motor drive units, connect the negative cable connectors. Ensure connector pins are properly aligned and seals are correctly positioned. Push connectors together until the locking mechanism engages with an audible click. Verify connection is secure by attempting to pull apart. Install protective covers on all connections.
16. 16

    Install new positive cable assembly
    Route the new positive cable assembly through the vehicle following the original path. Install all grommets, protective sleeves, and routing brackets. Ensure adequate clearance from all moving parts, heat sources, and sharp edges. Secure cable with all retaining hardware without over-compressing the cable insulation.
17. 17

    Connect positive cable to battery pack
    Position the positive cable lug onto the battery pack positive terminal. Clean mating surfaces and apply dielectric grease. Install terminal bolt and hand-tighten, then torque to specification per service manual. Install new terminal seal and protective cover. Verify connection is tight and properly sealed.
18. 18

    Connect positive cable to motors
    Connect the positive cable to both front and rear motor drive units. Align connectors carefully, ensure seals are properly positioned, and push together until locking mechanisms engage. Verify secure connection by pull-test. Install all protective covers on high-voltage connections.
19. 19

    Reinstall protective covers and skid plates
    Reinstall all underbody protective covers and skid plates in reverse order of removal. Ensure all fasteners are properly torqued and no cables are pinched or improperly routed. Verify adequate clearance for cable movement during suspension travel.
20. 20

    Re-energize high-voltage system
    Remove lockout device if installed. Reinstall the high-voltage service disconnect plug by aligning the key way and pushing firmly into the socket until fully seated. Install and secure the protective cover by turning clockwise. Reconnect the 12V auxiliary battery negative terminal.

Reassembly

1. Reinstall all rear cargo area floor panels and trim pieces
2. Ensure all high-voltage protective covers are properly installed and secured
3. Verify all cable routing clips and brackets are properly fastened
4. Double-check that no tools or parts have been left in the battery compartment or under the vehicle

Verification

• Connect Rivian diagnostic tool and power on the vehicle without starting drive mode
• Perform high-voltage system integrity check using diagnostic software
• Verify no high-voltage fault codes are present; address any codes before proceeding
• Monitor battery management system for proper voltage readings across all cells
• Perform insulation resistance test of high-voltage system (should be greater than 100 ohms per volt)
• Enable drive mode and verify both front and rear motors are operational
• Perform a low-speed test drive to confirm proper power delivery and no warning lights
• Re-check all cable connections and protective covers are secure after test drive
• Verify proper operation of regenerative braking system
• Clear any temporary diagnostic fault codes and verify no new codes appear

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