This procedure covers the removal and replacement of both positive and negative battery cables on the 2024 Rivian EDV 500's high-voltage battery system.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• Negative battery cable assembly × 1 — Use OEM specification
• Cable terminal hardware kit × 1 — Use OEM specification
• High-voltage connection seals × 2 — Use OEM specification

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Ensure vehicle is powered off completely and key fob is at least 20 feet away from vehicle
3. Open hood and secure with prop rod
4. Take detailed photos of all battery cable routing, clips, and connections
5. Disconnect the 12V auxiliary battery negative terminal and isolate the cable
6. Apply lock-out/tag-out procedures to prevent accidental vehicle activation
7. Put on high-voltage safety gloves and verify they have no damage or tears
8. Remove the high-voltage service disconnect cover located in the battery pack access area
9. Remove the high-voltage service disconnect plug and store it on your person

Procedure

1. 1

   Wait for capacitor discharge
   Wait a minimum of 15 minutes after removing the service disconnect to allow all high-voltage capacitors to safely discharge. Set a timer to ensure adequate wait time. Do not proceed until the full time has elapsed.
2. 2

   Verify system is de-energized
   Using a multimeter rated for at least 600V DC, verify zero voltage at the high-voltage battery terminals. Test between positive and negative terminals, then from each terminal to vehicle ground. All readings must show 0V DC before proceeding. If any voltage is detected, reinstall service disconnect, consult Rivian service documentation, and do not proceed.
3. 3

   Remove underbody panels
   Remove the necessary underbody panels to access the battery pack cable connections. On the EDV 500, this typically includes the front center panel and mid-section panels. Remove all fasteners and carefully lower panels away from vehicle. Support panels to prevent damage.
4. 4

   Disconnect positive cable from battery pack
   Locate the positive (orange-jacketed) cable connection at the battery pack. Remove the protective cover if present. Using insulated tools, remove the mounting bolts securing the positive cable terminal to the battery pack positive terminal. Note the exact orientation and any washers or spacers. Carefully lift the cable terminal straight off the battery post to avoid bending.
5. 5

   Disconnect positive cable from motor/inverter
   Follow the positive cable to the motor inverter assembly. Remove any cable retaining clips along the route. At the inverter connection, remove the protective cover and mounting hardware securing the positive cable terminal. Carefully disconnect the cable from the inverter, noting the orientation and any sealing components.
6. 6

   Remove positive cable routing hardware
   Release all cable routing clips, brackets, and support hardware securing the positive cable along its path. Keep track of all hardware locations using your reference photos. Remove any cable ties or secondary retention devices. Carefully route the positive cable out of the vehicle, ensuring it does not contact sharp edges or pinch points.
7. 7

   Disconnect negative cable from battery pack
   Locate the negative (orange-jacketed) cable connection at the battery pack. Remove the protective cover if present. Using insulated tools, remove the mounting bolts securing the negative cable terminal to the battery pack negative terminal. Note the exact orientation and any washers or spacers. Carefully lift the cable terminal straight off the battery post.
8. 8

   Disconnect negative cable from motor/chassis ground
   Follow the negative cable to its termination point at the motor housing or chassis ground location. Remove any cable retaining clips along the route. At the ground connection, remove the mounting hardware securing the negative cable terminal. Carefully disconnect the cable, noting the orientation and any grounding washers or star washers.
9. 9

   Remove negative cable routing hardware
   Release all cable routing clips, brackets, and support hardware securing the negative cable along its path. Keep track of all hardware locations using your reference photos. Remove any cable ties or secondary retention devices. Carefully route the negative cable out of the vehicle.
10. 10

    Inspect connection points and clean
    Thoroughly inspect all battery terminals, inverter connections, and ground points for corrosion, damage, or overheating evidence. Clean all connection surfaces with electrical contact cleaner if needed. Check that threads on battery posts and mounting points are clean and undamaged. Replace any damaged seals or insulators.
11. 11

    Route new positive cable
    Route the new positive battery cable through the vehicle following the exact path of the original cable as documented in your photos. Ensure the cable does not contact any sharp edges, moving components, or heat sources. The cable should have adequate slack but no excessive loops. Install all routing clips and brackets in their original locations, but do not fully tighten yet.
12. 12

    Connect positive cable to motor/inverter
    Install the new high-voltage connection seal on the inverter positive terminal if required. Position the positive cable terminal onto the inverter connection post in the exact orientation noted during disassembly. Install new mounting hardware from the kit and tighten evenly. Verify the connection is secure and the seal is properly seated. Install the protective cover.
13. 13

    Connect positive cable to battery pack
    Apply a thin layer of dielectric grease to the battery pack positive terminal. Position the positive cable terminal onto the battery positive post in the correct orientation. Install any washers or spacers in their original order. Install mounting bolts and tighten evenly in a cross pattern. Verify the connection is fully seated and secure.
14. 14

    Route new negative cable
    Route the new negative battery cable through the vehicle following the exact path of the original cable as documented in your photos. Ensure proper clearance from all components. The cable should have adequate slack but no excessive loops. Install all routing clips and brackets in their original locations, but do not fully tighten yet.
15. 15

    Connect negative cable to motor/chassis ground
    Clean the ground connection surface thoroughly. Position the negative cable terminal onto the ground connection point with any required star washers or grounding washers in place. Install mounting hardware and tighten securely to ensure a solid electrical ground connection. Verify the connection is flush and tight.
16. 16

    Connect negative cable to battery pack
    Apply a thin layer of dielectric grease to the battery pack negative terminal. Position the negative cable terminal onto the battery negative post in the correct orientation. Install any washers or spacers in their original order. Install mounting bolts and tighten evenly in a cross pattern. Verify the connection is fully seated and secure.
17. 17

    Secure all cable routing
    Verify all cable routing clips, brackets, and support hardware are properly installed per your reference photos. Tighten all routing hardware securely. Install new cable ties where original ties were cut. Ensure cables have proper clearance from moving parts, exhaust components, and sharp edges. Verify cables are not under tension or twisted.

Reassembly

1. Reinstall all underbody panels and secure with original fasteners
2. Reconnect the 12V auxiliary battery negative terminal
3. With high-voltage gloves still on, reinstall the high-voltage service disconnect plug into its receptacle
4. Install the service disconnect cover and secure properly
5. Remove lock-out/tag-out devices
6. Verify all tools and parts have been removed from under the vehicle and hood area

Verification

• Perform a visual inspection of all cable connections to ensure they are tight and properly seated
• Verify all protective covers and seals are installed on high-voltage connections
• Confirm all cable routing matches your reference photos with proper clearances
• Power on the vehicle and verify it completes the normal startup sequence without high-voltage system faults
• Check the vehicle's diagnostic system for any high-voltage battery or isolation resistance faults using appropriate scan tool
• Perform a test drive to verify normal vehicle operation and full power delivery from both motors
• After test drive, re-inspect all cable connections for signs of looseness, overheating, or movement

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