Battery Cable - Positive

This procedure covers the removal and replacement of the high-voltage positive battery cable on the 2024 Rivian EDV 500, including proper de-energization and safety protocols for the high-voltage system.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• High-voltage connector seals × 1 — Use OEM specification
• Cable mounting hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow high-voltage system to cool
3. Verify you have proper high-voltage safety training and certification before proceeding
4. Gather all required tools and replacement parts
5. Review vehicle service information for any technical service bulletins related to high-voltage system
6. Place warning tags on steering wheel indicating high-voltage work in progress
7. Ensure work area is dry and free from conductive materials

Procedure

1. 1

   Disconnect 12V battery
   Open the hood and locate the 12V auxiliary battery. Disconnect the negative terminal first, then the positive terminal. Isolate terminals to prevent accidental reconnection during the procedure.
2. 2

   Wait for system discharge
   Wait a minimum of 5 minutes after 12V battery disconnection to allow high-voltage system capacitors to fully discharge. This is a critical safety step and cannot be skipped.
3. 3

   Access high-voltage battery compartment
   Remove the underbody panels necessary to access the high-voltage battery pack. For the EDV 500, this typically requires removing the center underbody panel. Remove fasteners and carefully lower the panel, being mindful of any clips or secondary retention devices.
4. 4

   Don high-voltage safety equipment
   Put on Class 0 or higher rated high-voltage insulated gloves. Inspect gloves for any tears, punctures, or damage before use. Do not proceed if gloves are damaged.
5. 5

   Locate and unlock high-voltage service disconnect
   Locate the high-voltage service disconnect (manual service disconnect or MSD) on the battery pack. Follow manufacturer procedure to unlock and remove the service disconnect. This physically breaks the high-voltage circuit.
6. 6

   Verify de-energization
   Using a high-voltage capable multimeter, verify that voltage is not present at the positive battery cable connection point. Test between positive terminal and negative terminal, and positive terminal to vehicle ground. Voltage should read 0V DC. Do not proceed if any voltage is detected.
7. 7

   Remove high-voltage interlock connectors
   Disconnect the high-voltage interlock (HVIL) connectors from the positive cable assembly. These orange connectors provide system monitoring and must be disconnected before cable removal. Note the routing and orientation for reinstallation.
8. 8

   Disconnect positive cable at battery pack
   Remove the fasteners securing the positive cable terminal to the battery pack positive post. Keep track of all hardware including washers and lock washers. Carefully lift the cable terminal straight off the post to avoid damaging threads or sealing surfaces.
9. 9

   Disconnect positive cable at power distribution unit
   Trace the positive cable to its connection at the power distribution unit (PDU). Remove the fasteners securing the cable to the PDU positive terminal. Note the position of any ground straps or additional connections at this junction.
10. 10

    Remove cable routing clips and supports
    Carefully remove all cable routing clips, supports, and cable ties securing the positive cable along its path. Document or photograph the routing for proper reinstallation. The cable must follow the exact same path to maintain proper clearances and avoid chafing.
11. 11

    Remove positive cable assembly
    Carefully extract the positive cable assembly from the vehicle. Be extremely careful not to catch or damage the cable on any sharp edges. Inspect the cable path for any signs of contact or wear that may have contributed to cable failure.
12. 12

    Inspect connection points and clean terminals
    Inspect both the battery pack positive terminal and PDU positive terminal for any signs of corrosion, burning, or damage. Clean terminals with an appropriate terminal cleaning brush if necessary. Any damaged terminals must be addressed before installing new cable.
13. 13

    Route new positive cable
    Route the new positive cable assembly following the exact path documented during removal. Ensure the cable does not contact any sharp edges, moving parts, or hot surfaces. Verify adequate clearance at all points along the routing path.
14. 14

    Connect cable at battery pack
    Apply a thin coat of dielectric grease to the battery pack positive terminal. Position the cable terminal onto the post, ensuring proper alignment and full seating. Install fasteners and tighten according to manufacturer specifications. Since specific torque values are not available in the database, consult the vehicle service information for proper torque specifications.
15. 15

    Connect cable at power distribution unit
    Apply a thin coat of dielectric grease to the PDU positive terminal. Position the cable terminal, reinstall any ground straps or additional connections, and install fasteners. Tighten according to manufacturer specifications.
16. 16

    Secure cable routing
    Install all cable routing clips, supports, and cable ties to secure the positive cable in its proper position. Ensure the cable is supported at all required points and has no excessive slack that could cause movement or chafing.
17. 17

    Reconnect HVIL connectors
    Reconnect the high-voltage interlock connectors to the positive cable assembly. Ensure connectors are fully seated and locked. Verify the HVIL circuit continuity if testing equipment is available.
18. 18

    Reinstall high-voltage service disconnect
    Reinstall the high-voltage service disconnect (MSD) to the battery pack. Ensure it is fully seated and locked according to manufacturer procedures. The service disconnect must be properly engaged for the high-voltage system to function.
19. 19

    Reconnect 12V battery
    Reconnect the 12V auxiliary battery, positive terminal first, then negative terminal. Ensure connections are clean and tight.
20. 20

    Perform system initialization and testing
    Using the Rivian diagnostic tool or compatible scan tool, perform high-voltage system initialization procedures. Clear any diagnostic trouble codes that were set during the repair. Monitor system for proper operation and verify no new fault codes are present.

Reassembly

1. Reinstall all underbody panels removed for access, ensuring all fasteners and clips are properly secured
2. Perform a final visual inspection of all high-voltage connections and cable routing
3. Remove high-voltage work warning tags from vehicle
4. Document the repair including cable part number, installation date, and any observations

Verification

• Power on the vehicle and verify the high-voltage system activates without warning lights or error messages
• Using diagnostic tool, verify all high-voltage system monitors show normal operation
• Check for any unusual sounds, smells, or warning indicators during initial power-up
• Perform a test drive to verify normal vehicle operation and full power availability
• Scan for diagnostic trouble codes after test drive and verify none are present
• Visually inspect cable routing one final time to ensure no interference or contact points
• Verify HVIL system integrity through diagnostic tool if available

More procedures for this vehicle