This procedure covers the inspection, cleaning, and replacement of the high-voltage battery terminal connections on the 2023 Rivian EDV 500 electric delivery vehicle.

Warnings

Tools required

Parts

• Battery terminal connector (if corroded/damaged) × 1 — Use OEM specification
• Terminal hardware kit × 1 — Use OEM specification
• Battery terminal cover/insulator × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is in Park and powered off completely
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for systems to power down
4. Remove driver-side floor panel and access cover to expose HV disconnect location
5. Document the procedure with lockout/tagout tags indicating high-voltage work in progress
6. Put on high-voltage insulated gloves and verify they are free from damage or tears
7. Raise vehicle on service lift to access underbody battery pack (if required for terminal access)
8. Remove underbody skid plates and battery pack access panels as needed

Procedure

1. 1

   Disable high-voltage system
   Locate the manual service disconnect (MSD) plug in the front section of the battery pack. Pull the MSD handle firmly upward to disconnect the high-voltage system. The MSD should remain in the off position and secured with a lockout device. Verify the vehicle displays HV system disabled on any accessible screens.
2. 2

   Wait for capacitor discharge
   Wait a minimum of 5 minutes after removing the MSD to allow all high-voltage capacitors in the system to fully discharge. Do not proceed until the full waiting period has elapsed. Document the time on your work order.
3. 3

   Verify zero voltage
   Using a digital multimeter rated for high voltage, verify zero voltage (less than 5V DC) across the main battery terminals. Check voltage between positive and negative terminals, then between each terminal and vehicle ground. If any voltage above 5V is detected, do not proceed and investigate the cause.
4. 4

   Remove terminal protective covers
   Remove the orange high-voltage protective covers from both positive and negative battery terminals. These covers are typically secured with clips or fasteners. Inspect covers for damage and set aside for reinstallation or replacement.
5. 5

   Disconnect terminal cable harness
   Identify the main battery terminal connections. Remove any cable management clips or ties securing the harness. Working on the negative terminal first, remove the terminal mounting bolts using the appropriate socket. Support the cable to prevent it from falling and damaging connectors.
6. 6

   Remove positive terminal connection
   Remove the positive terminal mounting bolts in the same manner as the negative terminal. Carefully move the positive cable away from the terminal post and secure it to prevent accidental contact. Keep positive and negative cables separated.
7. 7

   Inspect terminals and connections
   Thoroughly inspect both battery terminals and cable ends for corrosion, discoloration, pitting, or damage. Check for loose strands in the cable, cracks in insulation, or signs of overheating. Inspect mounting surfaces on the battery pack for corrosion or damage. Document condition with photos if needed.
8. 8

   Clean terminals if serviceable
   If terminals show minor corrosion but are otherwise serviceable, clean both the battery terminal posts and cable connectors using a battery terminal cleaning brush. Remove all corrosion and oxidation. Wipe clean with a lint-free cloth. If terminals are heavily corroded, pitted, or damaged, they must be replaced rather than cleaned.
9. 9

   Apply dielectric grease
   Apply a thin layer of dielectric grease to the battery terminal posts and the inside of the cable connectors. This helps prevent future corrosion and ensures proper conductivity. Do not use excessive grease as it can attract contaminants.
10. 10

    Reconnect positive terminal
    Position the positive cable connector onto the positive battery terminal post, ensuring full seating and proper alignment. Install the mounting bolts and tighten to manufacturer specification using a torque wrench. Verify the connection is secure and the cable cannot rotate on the terminal.
11. 11

    Reconnect negative terminal
    Position the negative cable connector onto the negative battery terminal post in the same manner as the positive terminal. Tighten mounting bolts to specification. Double-check that both connections are fully seated and properly torqued.
12. 12

    Reinstall protective covers
    Install the orange high-voltage protective covers over both terminals, ensuring they are fully seated and all clips or fasteners are secured. These covers are critical safety components and must be properly installed. Secure any cable management clips or ties that were removed.
13. 13

    Reinstall access panels
    Reinstall all battery pack access panels and underbody skid plates that were removed. Ensure all fasteners are tightened to specification and panels are properly sealed to maintain environmental protection for the battery pack.
14. 14

    Re-enable high-voltage system
    Remove lockout device from the manual service disconnect. Push the MSD handle firmly down into the engaged position until it clicks and locks. Verify the MSD is fully seated and secured in the on position.
15. 15

    Reconnect 12V battery and test
    Reconnect the 12V auxiliary battery negative terminal. Power on the vehicle and verify all systems initialize normally. Check for any high-voltage system warning lights or error messages on the instrument cluster. Use diagnostic scan tool to check for any stored fault codes related to the HV system.

Reassembly

1. Ensure all high-voltage protective covers are properly installed and secured
2. Verify all underbody panels and skid plates are reinstalled with proper fasteners
3. Confirm cable management clips and ties are securing HV cables properly
4. Remove all lockout/tagout tags and account for all tools

Verification

• Power on vehicle and verify no warning lights related to high-voltage system are displayed
• Perform a test drive and verify normal acceleration and regenerative braking function
• Use diagnostic tool to scan for any HV system fault codes and verify none are present
• Verify battery state of charge is being displayed correctly and charging functions operate normally
• Perform a visual inspection of terminal area to confirm no loose hardware or improperly installed covers
• Document repair completion with final voltage measurements and any relevant diagnostic data

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