This procedure covers the removal and replacement of the engine bay fuse box on a 2024 Rivian EDV 500 dual motor AWD electric delivery vehicle.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box mounting grommets × 4 — Use OEM specification
• Wire harness connector seals × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Open the front hood and secure in open position
3. Disconnect the 12V auxiliary battery negative terminal and wait 10 minutes for system capacitors to discharge
4. Document or photograph all fuse positions and ratings in the existing fuse box
5. Label all wire harness connectors with their position using tape and marker or take detailed photographs
6. Remove any underhood covers or trim panels that obstruct access to the fuse box area
7. Verify you have the correct replacement fuse box and compare connector configurations before beginning removal

Procedure

1. 1

   Remove underhood access covers
   Remove the front underhood protective cover by releasing the plastic clips using a trim removal tool. Remove the Torx fasteners securing any secondary covers near the fuse box location on the driver side of the engine bay. Store all fasteners in a labeled container.
2. 2

   Disconnect primary power feed cables
   Locate the main power feed cables connected to the back of the fuse box. These will be large gauge cables with 10mm nuts. Use a 10mm socket to loosen and remove the nuts securing the power feed cables. Carefully move the cables aside and secure them away from the work area.
3. 3

   Disconnect wire harness connectors
   Identify all electrical connectors attached to the fuse box. Most Rivian connectors have a colored locking tab that must be lifted or pressed before the connector can be removed. Work methodically from one side to the other, releasing the locking mechanism on each connector and gently pulling straight back to disconnect. Do not pull on wires themselves. There are typically 4-6 large multi-pin connectors on the EDV 500 fuse box.
4. 4

   Remove ground straps
   Locate ground strap connections on or near the fuse box assembly. Use an 8mm or 10mm socket to remove the bolts securing ground straps to the fuse box mounting bracket or body. Keep track of ground strap locations as they must be reinstalled in the same positions.
5. 5

   Disconnect CAN bus and signal wires
   Locate smaller signal wire connectors and CAN bus connections. These are typically smaller connectors with gray, black, or blue housings. Carefully depress the locking tabs and disconnect each connector. Take extra care with these as the pins are smaller and more delicate than the power connectors.
6. 6

   Remove fuse box mounting fasteners
   Locate the mounting bolts securing the fuse box to the body or mounting bracket. These are typically 10mm bolts at each corner of the fuse box assembly. Remove all mounting bolts and keep them organized. Check for any hidden clips or tabs that may also secure the fuse box in position.
7. 7

   Remove fuse box assembly
   With all connections and fasteners removed, carefully lift the fuse box assembly up and out of the engine bay. The fuse box may have wire harness routing clips underneath, so lift straight up and then angle as needed to clear any obstructions. Be mindful of any remaining wire harness routing that may restrict movement.
8. 8

   Transfer fuses and relays
   Using your documentation from the preparation phase, remove all fuses and relays from the old fuse box and transfer them to the corresponding positions in the new fuse box. Verify each fuse rating matches the diagram on the fuse box cover. Inspect each fuse for signs of burning or damage and replace if necessary.
9. 9

   Install new fuse box assembly
   Position the new fuse box assembly into the mounting location in the engine bay. Align the mounting holes with the bracket or body. Install the mounting bolts finger-tight initially to allow for adjustment. Once all bolts are started, tighten them evenly in a cross pattern to secure the fuse box without warping the housing.
10. 10

    Reconnect ground straps
    Reinstall all ground straps to their original positions on the fuse box mounting bracket or body. Ensure mating surfaces are clean and free of paint or corrosion. Tighten ground strap bolts securely to ensure good electrical contact.
11. 11

    Reconnect all electrical connectors
    Beginning with the large multi-pin connectors, reconnect each harness connector to the new fuse box. Align the connector carefully with its receptacle and push firmly until you hear or feel a click. Verify the locking tab engages properly on each connector. Work through all CAN bus and signal wire connectors as well, ensuring each is fully seated.
12. 12

    Reconnect power feed cables
    Reconnect the main power feed cables to the back of the fuse box. Place the cable terminals over the studs and install the 10mm nuts. Tighten securely to ensure good electrical contact but do not overtighten and strip the threads on the fuse box posts.
13. 13

    Reinstall protective covers
    Reinstall all underhood covers and trim panels that were removed during disassembly. Ensure all clips and Torx fasteners are properly secured. Verify no wires or connectors are pinched between panels.

Reassembly

1. Double-check that all electrical connectors are fully seated with locking tabs engaged
2. Verify all fuses and relays are installed in correct positions according to fuse box diagram
3. Ensure no tools or parts have been left in the engine bay
4. Reconnect the 12V auxiliary battery negative terminal

Verification

• Turn the vehicle to ON mode (do not start) and verify the instrument cluster illuminates without warning lights related to electrical system faults
• Use a multimeter to verify proper voltage at key fuse positions (12V nominal)
• Test operation of all major electrical systems: headlights, wipers, HVAC, power windows, and infotainment
• Perform a test drive and verify all vehicle systems operate normally
• Check for any warning messages on the instrument cluster or infotainment screen
• Verify proper operation of the charging system by connecting to a charger
• If any fault codes are present, use Rivian diagnostic software to read and clear them, then retest to ensure they do not return

More procedures for this vehicle