High Voltage Cable Inspection

Comprehensive visual and electrical inspection of high voltage cables, connections, and shielding on the Rivian EDV 500 dual motor system to identify wear, damage, or degradation that could compromise safety or performance.

Warnings

Tools required

Parts

• High voltage cable protective boots (if damaged) × 1 — Use OEM specification
• High voltage connector seals (if damaged) × 1 — Use OEM specification
• Cable retention clips (if damaged) × 1 — Use OEM specification
• High voltage warning labels (if missing or damaged) × 1 — Use OEM specification

Preparation

1. Verify you have completed manufacturer-approved high voltage safety training and possess current certification
2. Ensure a second qualified person is present throughout the entire procedure
3. Verify all high voltage safety equipment (gloves, face shield, insulated tools) is within calibration period and visually inspect for damage
4. Park vehicle on level surface and engage parking brake
5. Ensure vehicle has been shut down for minimum 30 minutes to allow high voltage system cooling
6. Place high voltage warning cones or barriers around the vehicle work area
7. Connect Rivian diagnostic scan tool and verify no active high voltage system faults before beginning
8. Document initial vehicle state including any warning lights, error codes, or customer concerns
9. Take photographs of all high voltage cable routing and connections before disturbing any components
10. Verify fire extinguisher rated for electrical fires (Class C) is immediately accessible
11. Ensure adequate ventilation in work area in case of battery thermal event

Procedure

1. 1

   De-energize the high voltage system
   Turn vehicle to OFF mode and remove key fob from vehicle interior. Open hood and locate the 12V service disconnect located in the front compartment. Remove the 12V service disconnect cover and disconnect the 12V negative terminal. Wait 5 minutes for vehicle control modules to fully power down. Locate the high voltage service disconnect (typically under rear seat or in battery pack access panel per service manual). Using insulated tools, remove the high voltage service disconnect following manufacturer sequence. Install lockout/tagout device on both 12V and HV disconnects. Wait an additional 10 minutes for high voltage capacitors to discharge.
   ⚠️Disconnecting the 12V system alone does NOT de-energize high voltage cables. Both disconnects must be removed.
   ⚠️Do not skip the 10 minute capacitor discharge waiting period. Capacitors can retain lethal voltage.
2. 2

   Verify system de-energization
   Put on Class 0 insulated gloves and face shield. Using a high voltage rated multimeter (CAT III 1000V minimum), verify zero voltage at the high voltage service disconnect location. Test meter function on a known voltage source immediately before and after to confirm meter is working correctly. Measure voltage at multiple high voltage connection points including motor controllers and battery pack terminals. All readings must be below 5V DC. Document all voltage readings. Only proceed if all measurements confirm de-energization.
   ⚠️Always test your meter on a known voltage source before and after verifying de-energization to ensure meter is functioning correctly. A faulty meter could indicate false zero readings.
3. 3

   Raise vehicle and remove underbody panels
   Raise vehicle on lift to comfortable working height. Remove plastic underbody panels to access high voltage cable routing between battery pack, front motor controller, and rear motor controller. Remove the front and rear skid plates if equipped. Document all fastener locations. Support any loose panels to prevent damage. Ensure all high voltage cables are now visible for inspection along their entire run from battery pack to both motor controllers.
4. 4

   Initial visual inspection of cable routing and retention
   Perform systematic visual inspection of all orange high voltage cables from battery pack to front motor, battery pack to rear motor, and any interconnecting cables. Verify cables are properly secured in all retention clips and mounting points. Check for any signs of cable sagging, improper routing, or contact with chassis/suspension components. Verify minimum clearance of 25mm (1 inch) between high voltage cables and any moving parts (suspension, driveshafts, steering components). Document any deviations from proper routing with photographs and measurements.
   ⚠Cables touching or routing near moving suspension components indicate improper installation and present chafing risk leading to insulation failure.
5. 5

   Inspect cable insulation and shielding
   Carefully examine the orange outer insulation of all high voltage cables along their entire length. Look for cuts, abrasions, punctures, melting, discoloration, or other damage. Use inspection mirror to view areas not directly visible. Check for any exposure of the inner cable conductors or metallic shielding through the orange insulation. Inspect the braided metallic shielding where visible at connectors for corrosion, fraying, or damage. Any compromise to insulation integrity requires cable replacement. Measure cable diameter at multiple points and compare to service specifications to detect internal conductor damage or insulation swelling.
   ⚠️Even minor cuts or abrasions in high voltage cable insulation can allow moisture intrusion leading to tracking, arcing, and potential fire. Any insulation damage requires immediate cable replacement.
6. 6

   Inspect high voltage connectors and seals
   Examine all high voltage connectors at the battery pack, front motor controller, and rear motor controller. Check connector housings for cracks, damage, or discoloration indicating overheating. Verify orange connector locks are properly engaged and not broken. Inspect the rubber seals and boots at each connector for cracking, tears, missing sections, or deterioration. Verify all connector seal retention features are intact. Check for any signs of moisture, corrosion, or contamination inside connector areas (use inspection light). Verify high voltage interlock connectors are properly seated with no damage to pins or housings.
   ⚠Discoloration or melting at connector housings indicates overheating from poor connection or excessive resistance. This requires connector replacement and investigation of root cause.
7. 7

   Check for thermal damage and discoloration
   Look for any heat-related damage on cables and connectors including discoloration, melting, or deformation of insulation. If available, use thermal imaging camera to review stored vehicle operational data or perform comparative thermal analysis if safe testing can be conducted. Check areas where cables pass near heat sources like motors and inverters for heat degradation. Examine cable insulation flexibility by gently manipulating accessible sections - insulation should remain pliable, not brittle or cracked. Document any thermal damage with photographs and measurements.
   ⚠Brittle or stiff cable insulation indicates thermal or age-related degradation and compromised dielectric strength. Affected cables must be replaced.
8. 8

   Inspect cable bend radius and strain relief
   Verify all high voltage cables maintain proper bend radius throughout their routing. Rivian specifications typically require minimum bend radius of 10 times cable diameter for dynamic sections and 5 times for static sections. Measure any questionable bends using appropriate tools. Examine strain relief boots at all connectors for proper installation and condition. Verify cables are not under tension or experiencing pull forces at connectors. Check that cable retention points distribute support evenly without creating stress concentration points.
   ⚠Excessive cable bending can damage internal conductors and reduce current carrying capacity, potentially causing overheating and insulation failure.
9. 9

   Check for contamination and environmental damage
   Inspect all high voltage cables and components for contamination from oil, coolant, brake fluid, or other automotive fluids. Check for accumulation of road salt, mud, or debris that could trap moisture against cables. Examine areas where cables pass through bulkheads or grommets for proper sealing and water intrusion protection. Verify all cable drain holes and breather vents are clear and functional. Look for signs of rodent damage including chew marks or nesting material near cables. Document any contamination or environmental concerns.
   ⚠Fluid contamination on high voltage cables can degrade insulation and create tracking paths for electrical leakage. Clean and verify insulation integrity if contamination is found.
10. 10

    Verify high voltage warning labels
    Check that all high voltage warning labels are present, legible, and properly adhered at required locations. Verify labels are present on battery pack, motor controllers, high voltage junction boxes, and along cable routes per service manual requirements. Replace any missing, damaged, or illegible warning labels with OEM replacements. Confirm that orange marking on all high voltage cables is continuous and clearly visible. Document any missing labels and their locations.
11. 11

    Perform insulation resistance testing
    Using a calibrated megohmmeter rated for 1000V DC, perform insulation resistance tests on all high voltage cables. Test between each high voltage conductor and vehicle chassis/ground. Also test between positive and negative high voltage conductors at the service disconnect location. Apply test voltage per manufacturer specification (typically 500-1000V DC for 5-10 seconds). Record all insulation resistance values. Minimum acceptable insulation resistance is typically 500 megohms, but verify against Rivian specifications. Any reading below specification indicates insulation degradation and requires cable replacement.
    ⚠️Megohmmeter testing applies high voltage to the cables. Verify all personnel are clear of the vehicle and high voltage components before applying test voltage.
    ⚠Low insulation resistance readings indicate compromised cable insulation and present serious safety hazard. Do not return vehicle to service until affected cables are replaced.
12. 12

    Inspect battery coolant lines near HV cables
    Examine the EV Battery/Motor Coolant lines that run adjacent to high voltage cables. Check for any coolant leaks, damaged hoses, or loose connections that could drip coolant onto high voltage cables. Verify coolant lines maintain proper separation from HV cables with no contact points. Inspect coolant line routing clips and supports for security. Check coolant level in reservoir and verify no loss indicating leaks. Any coolant contamination on high voltage components must be cleaned and investigated.
    ⚠Coolant leaks onto high voltage cables create electrical hazards and insulation degradation. Address any coolant system issues before returning vehicle to service.
13. 13

    Document findings and create inspection report
    Compile all inspection findings, measurements, test results, and photographs into comprehensive inspection report. Document cable condition, connector integrity, insulation resistance values, and any deficiencies found. Note any cables or components requiring replacement. Record all replaced parts and components. Create list of any follow-up actions required. If any safety-critical issues were identified, clearly mark vehicle as not safe to operate until repairs are completed. Prepare estimate for any necessary repairs or component replacements.

Reassembly

1. Replace any damaged cable retention clips, connector seals, or protective boots identified during inspection
2. Install any missing or damaged high voltage warning labels with OEM replacements
3. Verify all high voltage cables are properly routed in original positions using reference photographs taken during disassembly
4. Reinstall all underbody panels and skid plates, ensuring no panels contact or put pressure on high voltage cables
5. Reinstall high voltage service disconnect following manufacturer procedure - ensure positive engagement
6. Reinstall 12V negative terminal and service disconnect
7. Remove lockout/tagout devices only after all work is complete and verified

Verification

• Connect diagnostic scan tool and verify no high voltage system fault codes are present
• Perform high voltage system initialization procedure using scan tool per manufacturer specification
• Verify high voltage system ready indicator illuminates on instrument cluster when vehicle is powered on
• Monitor high voltage system status on scan tool during vehicle ready mode - verify all voltage readings are normal and stable
• Perform functional test by operating vehicle in forward and reverse at low speed to verify both motors energize properly
• Recheck all high voltage cable routing and retention points with vehicle at normal operating height
• Verify no unusual sounds, smells, or warning messages during initial test operation
• Document post-inspection system verification results and attach to inspection report
• If any insulation resistance values were below specification or any cable damage was found, vehicle must not be returned to customer until repairs are completed and re-inspection passes all criteria
• Provide customer with detailed report of inspection findings and any recommendations for future monitoring or service

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