High Voltage Wiring Harness

This procedure covers the inspection, removal, and replacement of the high voltage wiring harness connecting the battery pack to the dual motor drive units on the 2023 Rivian EDV 500.

Warnings

Tools required

Parts

• High voltage wiring harness assembly × 1 — Use OEM specification - Rivian part specific to EDV 500
• High voltage connector seals × 4 — Use OEM specification
• Cable retention clips × 8 — Use OEM specification
• High voltage interlock connector × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake. Ensure vehicle has been off for minimum 30 minutes to allow systems to power down
2. Verify no diagnostic trouble codes related to high voltage system before beginning work. Address any existing faults first
3. Connect Rivian diagnostic scanner and navigate to Service Mode. Enable 'High Voltage Service Disconnect' mode to open contactors
4. Remove the front cargo area floor panels and locate the high voltage service disconnect under the hood area
5. Wearing high voltage safety gloves, unlock and remove the high voltage service disconnect plug. Install lockout/tagout device to prevent reconnection
6. Wait minimum 5 minutes for high voltage system capacitors to fully discharge
7. Using CAT III rated multimeter with insulated probes, verify zero voltage at battery pack terminals and motor controller inputs. Voltage must read less than 5V DC
8. Place 'HIGH VOLTAGE WORK IN PROGRESS' warning signs at all vehicle access points
9. Disconnect 12V auxiliary battery negative terminal to prevent accidental system wake-up
10. Photograph all high voltage harness routing, retention points, and connector orientations from multiple angles

Procedure

1. 1

   Remove underbody protective panels
   Remove the center underbody panel fasteners using 8mm and 10mm sockets. Lower the protective panels to access the high voltage harness routing between the battery pack and drive units. Keep fasteners organized as panel positions are specific.
2. 2

   Disconnect high voltage interlock system
   Locate the orange high voltage interlock connector on the main harness. Press the locking tab and carefully disconnect the interlock circuit. This two-wire connector creates a safety loop that monitors harness integrity. Tag this connector for reassembly reference.
3. 3

   Disconnect rear motor high voltage connector
   At the rear drive unit, locate the orange high voltage connector. Slide the orange safety lock outward to unlock position. Press both locking tabs simultaneously while pulling the connector straight back from the motor controller. Support the weight of the connector to prevent cable strain. Inspect connector pins and housing for any damage or corrosion.
4. 4

   Disconnect front motor high voltage connector
   At the front drive unit, locate the orange high voltage connector. Follow same disconnection procedure as rear motor: unlock orange safety, press both locking tabs, pull straight back. The front connector may have a protective boot that must be slid back first. Support connector weight during removal.
5. 5

   Disconnect battery pack high voltage connectors
   At the battery pack junction, locate the two high voltage output connectors (positive and negative busbars). These use quarter-turn locking mechanisms. Rotate the orange safety collar counterclockwise, then rotate the connector body counterclockwise one-quarter turn to unlock. Pull straight out from busbar. Mark positive and negative positions clearly.
6. 6

   Release cable retention points
   Working from battery pack toward drive units, release all cable retention clips and hangers securing the high voltage harness. These are typically push-type clips integrated into the chassis rails. Count and document locations of all retention points. Use cable support stands to prevent harness from dropping or straining.
7. 7

   Separate harness from chassis routing channels
   Carefully guide the high voltage harness out of the chassis routing channels and protective conduits. The harness routes through specific grooves and may have foam protective wrapping at contact points. Note all locations where protective materials are installed. Work slowly to avoid snagging on chassis components.
8. 8

   Remove harness assembly
   With all connections and retention points released, carefully lower the high voltage harness assembly from the vehicle. This is a heavy component requiring two people for safe handling. Place on clean, non-conductive work surface for inspection. Check removed harness for any signs of damage, chafing, or connector corrosion that may have necessitated replacement.
9. 9

   Prepare new harness for installation
   Unpack new high voltage harness and verify part number matches vehicle specification for EDV 500 dual motor configuration. Inspect all connectors for shipping damage. Apply thin coat of dielectric grease to connector O-rings and sealing surfaces (if not pre-applied). Compare new harness routing and branch lengths to photographs of original installation.
10. 10

    Route new harness through chassis
    With assistance, lift new harness into position following documented routing path. Thread harness through chassis channels and protective conduits, ensuring orange high voltage identification remains visible. Position branch connections near their respective connection points. Use cable support stands to maintain position without strain on connectors.
11. 11

    Install cable retention clips
    Secure harness at all documented retention points using new clips or reusing original clips if in good condition. Ensure harness sits properly in chassis grooves with no tension or sharp bends. Maintain minimum 50mm clearance from exhaust components, sharp edges, and moving suspension parts. Install protective foam wrapping at chassis contact points matching original locations.
12. 12

    Connect battery pack high voltage connectors
    At battery pack junction, align positive connector (marked with red identification) to positive busbar. Push connector straight onto busbar until seated, rotate clockwise one-quarter turn to lock, then rotate orange safety collar clockwise to secure. Repeat for negative connector. Verify both connectors are fully locked with no gaps between connector body and busbar face.
13. 13

    Connect drive unit high voltage connectors
    Connect front motor high voltage connector by aligning pins and pushing straight onto controller until fully seated with audible click. Install orange safety lock by sliding fully into locked position. Repeat procedure for rear motor connector. Verify positive engagement on both connectors by attempting gentle pull-back while holding motor controller housing.
14. 14

    Reconnect high voltage interlock system
    Reconnect the orange high voltage interlock connector, ensuring it clicks fully into locked position. This must be connected for the vehicle to enable high voltage systems. Gently tug connector to verify locking tab engagement. The interlock circuit monitors harness integrity and will prevent operation if open.
15. 15

    Perform electrical verification
    With all connections complete but service disconnect still removed, reconnect 12V auxiliary battery. Connect diagnostic scanner and verify high voltage interlock circuit shows closed/intact status. Check for any new diagnostic trouble codes. All codes should relate to service disconnect being removed, with no harness continuity or insulation resistance faults present.

Reassembly

1. Reinstall underbody protective panels in reverse order of removal, ensuring all fasteners are properly seated
2. Perform final visual inspection of all high voltage connections, verifying orange safety locks are engaged and no gaps exist at connector interfaces
3. Remove lockout/tagout device and reinstall high voltage service disconnect plug, pushing firmly until it clicks into locked position
4. Exit Service Mode on diagnostic scanner to allow high voltage system re-energization

Verification

• With diagnostic scanner connected, cycle vehicle to ON position without starting. Monitor for successful high voltage system initialization and battery pack contactor closure
• Verify zero diagnostic trouble codes related to high voltage system, insulation resistance, or interlock circuits
• Check voltage readings at all three high voltage junction points using scanner data stream. Battery voltage should be present at both motor controllers when vehicle is in READY mode
• Perform low-speed test drive in safe area, verifying both front and rear motors engage properly during acceleration and regenerative braking functions normally
• Perform final insulation resistance test using diagnostic scanner high voltage system test procedures. All circuits must show greater than 100 ohms per volt insulation resistance
• Inspect all harness routing points while vehicle is on lift, checking for any movement, contact with chassis, or clearance issues
• Clear Service Mode history and document repair in vehicle service records with harness part number and installation date

Related trouble codes on this vehicle

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