This procedure covers the removal and replacement of a generic electrical relay in the 2023 Rivian EDV 500 commercial delivery van. Relays control various electrical systems including HVAC, lighting, charging, and auxiliary power circuits.

Warnings

Tools required

Parts

• Replacement relay (appropriate amperage rating) × 1 — Use OEM specification - verify relay type and rating from vehicle label or diagnostic software
• Dielectric grease × 1 — Generic electrical contact protection

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off the vehicle completely and remove the key fob from the cabin
3. Wait at least 5 minutes for capacitors to discharge
4. Use diagnostic software to identify the specific relay causing the fault code or symptom
5. Locate the relay position using wiring diagrams or the relay map on the fuse box cover
6. Disconnect the 12V auxiliary battery (located under hood or rear cargo area depending on model year configuration) by removing the negative terminal first
7. Verify all electrical systems are de-energized using a multimeter

Procedure

1. 1

   Access the relay location
   Remove any panels, covers, or trim pieces necessary to access the relay. For underhood relays, open the hood and remove the power distribution module cover. For interior relays, remove the appropriate lower dash panel or kick panel using trim removal tools. For rear cargo area relays, remove the access panel on the driver side rear.
2. 2

   Identify and photograph the relay
   Locate the specific relay to be replaced using the relay map on the cover or the diagnostic information. Take a photograph of the relay orientation and position for reference. Note the relay amperage rating and part number printed on the relay body.
3. 3

   Test the existing relay
   If possible, use a multimeter to test the relay coil resistance (typically between 50-200 ohms across the control terminals) and verify contact continuity when energized. Document readings. If the relay is functioning but suspected, mark it for bench testing rather than immediate disposal.
4. 4

   Remove the faulty relay
   Firmly grasp the relay body and pull straight up or out from the socket. Some relays may have a locking tab that must be pressed before removal. If the relay is secured with a bracket or bolt, remove the fastener first. Avoid rocking the relay side-to-side as this can damage the socket pins.
5. 5

   Inspect the relay socket
   Examine the socket terminals for corrosion, discoloration, or damage. Look for signs of overheating such as melted plastic or burned contacts. If corrosion is present, clean terminals with a wire brush or electrical contact cleaner. If socket damage is evident, the entire junction box may need replacement or socket repair.
6. 6

   Verify replacement relay specifications
   Compare the replacement relay to the original, ensuring the amperage rating, voltage rating, coil voltage, and pin configuration match exactly. Rivian uses both standard automotive micro-relays and mini-relays depending on application. Installing an incorrect relay can cause system malfunction or fire.
7. 7

   Apply dielectric grease to terminals
   Apply a small amount of dielectric grease to the socket terminals to prevent corrosion and ensure good electrical contact. Do not over-apply as excess grease can attract contaminants.
8. 8

   Install the new relay
   Align the relay pins with the socket, ensuring correct orientation based on your reference photo. Press firmly and evenly until the relay is fully seated in the socket. The relay should sit flush with no gaps. If equipped with a retaining clip or bracket, reinstall and secure it.
9. 9

   Reconnect the 12V battery
   Reconnect the 12V auxiliary battery, connecting the positive terminal first, then the negative terminal. Ensure connections are clean and tight.
10. 10

    Test the relay function
    Power on the vehicle and use the diagnostic software to clear any stored fault codes. Activate the system controlled by the relay (e.g., HVAC blower, auxiliary power outlet, lighting circuit) and verify proper operation. Monitor for any unusual sounds or behaviors.
11. 11

    Reinstall access panels
    Once function is verified, reinstall all covers, panels, and trim pieces removed during access. Ensure all clips and fasteners are properly secured.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify no tools or parts were left in the engine compartment or cabin
3. Confirm all panels and covers are properly secured with no gaps or loose clips

Verification

• Start the vehicle and verify no warning lights or fault codes are present on the instrument cluster
• Use diagnostic software to scan for DTCs and verify the original fault code has cleared
• Activate the system controlled by the replaced relay multiple times to confirm consistent operation
• For high-current relays (HVAC, charging), monitor the relay area for heat after 10-15 minutes of operation to ensure proper function
• Test drive the vehicle if the relay controls a system used during driving (lights, wipers, etc.)

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