This procedure covers the removal and replacement of the engine bay fuse box on a 2023 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box mounting bracket hardware kit × 1 — Use OEM specification
• Wiring harness connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from cabin
3. Open hood and secure with hood prop
4. Photograph fuse box location, all connectors, and fuse positions for reference
5. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
6. Use masking tape and marker to label all electrical connectors before disconnection
7. Verify no active warning lights or systems are running

Procedure

1. 1

   Remove fuse box cover
   Release the fuse box cover by pressing the tabs on both sides of the cover. Lift the cover upward and away from the fuse box housing. Inspect the cover gasket for damage and set aside in a clean area.
2. 2

   Document and remove fuses
   Photograph or create a diagram of all fuse positions. Using the fuse puller tool located inside the fuse box cover, carefully remove all fuses and relays from the fuse box. Place them in organized containers labeled by position to ensure correct reinstallation.
3. 3

   Disconnect primary wiring harness connectors
   Locate the main wiring harness connectors on the rear and side of the fuse box. Press down on the connector release tabs while pulling the connectors straight away from the fuse box. There are typically 3-5 large connectors supplying power and control signals. Use gentle rocking motion if connectors are tight, but do not force.
4. 4

   Remove secondary and ground connections
   Disconnect any remaining smaller auxiliary connectors attached to the fuse box. Using a 10mm socket, remove the ground wire connections from the mounting points on the fuse box housing. Keep all ground wires and hardware together.
5. 5

   Remove fuse box mounting fasteners
   Using a 12mm socket, remove the mounting bolts securing the fuse box to the bracket. Typical installations have 3-4 mounting bolts. Note the location of any spacing washers or insulators under the fuse box for proper reinstallation. Set hardware aside in a container.
6. 6

   Remove mounting bracket if necessary
   If the mounting bracket is damaged or needs replacement, use T30 Torx driver to remove the bracket mounting screws from the body panel. The bracket typically has 4-6 mounting points. Inspect the body panel mounting points for damage or corrosion.
7. 7

   Extract fuse box from engine bay
   Carefully lift the fuse box assembly upward and away from the mounting location. Guide any attached wiring through openings while ensuring no wires are snagged or pinched. Inspect the mounting area for debris, corrosion, or moisture intrusion.
8. 8

   Inspect and prepare mounting area
   Clean the fuse box mounting area and bracket with electrical contact cleaner and a lint-free cloth. Inspect all body panel mounting points for damage. Check that all rubber grommets and seals in wire pass-through locations are intact. Replace any damaged seals.
9. 9

   Install mounting bracket on new fuse box
   If removed, position the mounting bracket on the new or replacement fuse box. Install the bracket mounting screws and tighten in a cross pattern to ensure even seating. Verify the bracket is properly aligned before final tightening.
10. 10

    Position and secure new fuse box
    Carefully lower the new fuse box into position, guiding wiring harnesses through appropriate openings. Align the mounting holes with the bracket or body panel mounting points. Install the mounting bolts with any original spacers or insulators in their correct positions. Tighten bolts in a cross pattern to 12mm socket snug specification.
11. 11

    Reconnect ground connections
    Reattach all ground wires to their original mounting points on the fuse box or nearby body panels using 10mm socket. Ensure ground contact surfaces are clean and free of paint or corrosion. Tighten ground connections firmly.
12. 12

    Reconnect wiring harness connectors
    Reconnect all main wiring harness connectors to the fuse box, referencing your labels and photographs. Push each connector firmly until you hear or feel a positive click. Verify the connector lock tabs are fully engaged. Double-check that no pins are bent or misaligned.
13. 13

    Reinstall fuses and relays
    Using your documentation from removal, reinstall all fuses and relays in their correct positions. Ensure each fuse is fully seated in its socket. Verify fuse ratings match the fuse box diagram on the cover.
14. 14

    Reconnect battery and test systems
    Reconnect the 12V auxiliary battery negative terminal. Turn the vehicle to ON position without starting. Verify the instrument cluster illuminates properly with no unexpected warning lights. Test critical systems including lights, wipers, HVAC, and power windows to confirm fuse box functionality.

Reassembly

1. Reinstall the fuse box cover ensuring the gasket is properly seated
2. Press firmly on all sides of the cover until tabs click into place
3. Verify all connectors have secure locking tabs engaged
4. Check that no wiring is pinched or under tension
5. Ensure all ground connections are tight and corrosion-free

Verification

• Turn vehicle to ON position and verify no fuse box related warning lights appear on instrument cluster
• Test all electrical systems systematically: headlights, turn signals, brake lights, wipers, HVAC, power windows, and infotainment
• Verify charging system indicator shows normal operation
• Check for any unusual smells, smoke, or heat from fuse box area
• Perform a short test drive to confirm all vehicle systems function normally under load
• Scan for diagnostic trouble codes using appropriate scan tool and address any new codes

More procedures for this vehicle