High Voltage Cable Inspection

Visual and physical inspection of high voltage cables, connectors, and protective shields on the dual-motor AWD electric drivetrain to identify damage, wear, or insulation deterioration that could cause electrical faults or safety hazards.

Warnings

Tools required

Parts

• High voltage safety labels/warning stickers × 1 — Use OEM specification
• Cable routing clips and ties × 1 — Use OEM specification
• HV connector seals (if damage found) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow components to cool
3. Verify you have appropriate personal protective equipment: HV gloves, safety glasses, insulated footwear
4. Review vehicle-specific service information and HV system layout diagrams
5. Ensure fire extinguisher rated for electrical fires (Class C) is immediately accessible
6. Clear work area of unnecessary personnel - only qualified technicians should be present
7. Document current vehicle mileage and any active fault codes using diagnostic tool

Procedure

1. 1

   Disable high voltage system and verify de-energization
   Using the Rivian diagnostic tool, command the HV system to service mode which opens all contactors. Alternatively, access the HV service disconnect located in the rear cargo area under the load floor panel. Remove the service disconnect plug and install lockout device. Wait minimum 15 minutes for capacitor discharge. Using CAT IV multimeter, verify voltage at battery terminals is below 5V DC. Document voltage reading and time.
2. 2

   Raise and support vehicle
   Lift vehicle using approved lift points specified in service manual (typically reinforced frame rails behind front wheels and ahead of rear wheels). Raise to comfortable working height to access underbody. Verify vehicle is stable before working underneath. Remove undertray panels and protective shields to expose HV cables if necessary.
3. 3

   Initial visual inspection of battery HV output cables
   Locate the main HV cables exiting the battery pack (typically orange cables, approximately 25-35mm diameter). Inspect cable routing from battery pack to drive units. Look for: physical damage to orange outer insulation, abrasion marks, thermal discoloration or melting, contact with sharp edges, improper routing against chassis components, compression damage from mounting points, and evidence of fluid contamination. Document any findings with photographs noting specific location.
4. 4

   Inspect HV connector integrity at battery pack
   Examine HV connectors at battery pack terminals without disconnecting. Check connector housings for cracks, discoloration, or deformation. Verify locking mechanisms are fully engaged. Check for corrosion on exposed connector surfaces. Inspect weather seals and boots for tears, brittleness, or improper seating. Look for evidence of arcing (black carbon deposits or melted material). Ensure safety cover plates are intact and properly secured.
5. 5

   Inspect front drive unit HV cables
   Trace HV cables from battery pack forward to front drive motor/inverter assembly. Inspect entire cable length for damage, ensuring cables are properly secured in all mounting clips and have adequate clearance from suspension components, steering components, and subframe. Check for witness marks indicating contact during suspension travel. Verify heat shields are present and properly positioned where cables route near exhaust or high-temperature components.
6. 6

   Inspect rear drive unit HV cables
   Trace HV cables from battery pack rearward to rear drive motor/inverter assembly. Inspect entire cable length following same criteria as front cables. Pay particular attention to routing through tunnel or underfloor areas where damage from road debris is more likely. Check cable support brackets for damage or looseness. Verify proper clearance from driveline components and rear suspension.
7. 7

   Inspect HV connectors at drive units
   Examine HV connectors at both front and rear drive unit inverters. Check connector housing condition, locking mechanism engagement, and seal integrity. Look for coolant leaks at inverter housing near HV connections as coolant contamination can compromise insulation. Inspect for signs of overheating such as discolored connectors or melted plastic. Verify safety covers and shields are present.
8. 8

   Inspect charging system HV cables
   Locate HV cables routing from battery pack to charging inlet (typically front driver side or passenger side). Inspect cable condition along entire route. Examine charging port connector and internal contacts for damage, corrosion, or arcing damage. Check that charging port door operates smoothly and weather seals are intact. Verify pilot pin and communication pins show no damage.
9. 9

   Inspect HV heater and HVAC system cables (if equipped)
   Locate HV cables supplying cabin heater and battery thermal management system. These may route forward to front compartment. Inspect cable condition and routing. Check connections at HV heater unit and thermal management components. Verify proper clearance from coolant hoses and HVAC refrigerant lines.
10. 10

    Perform insulation resistance test
    Using megohmmeter set to 1000V DC, perform insulation resistance test on HV system. Test between HV+ bus and vehicle chassis ground, then HV- bus and chassis ground. Acceptable reading should be greater than 100 megohms minimum (consult service data for specific threshold). Lower readings indicate insulation degradation. Document all readings. If readings are marginal or failing, further diagnosis is required to isolate the affected cable section.
11. 11

    Inspect cable shield grounding points
    HV cables have outer braided shields that must be properly grounded at specific points. Inspect shield terminations for corrosion, loose connections, or damage. Verify grounding straps are intact and securely fastened to chassis ground points. Check ground connection torque if accessible (refer to service data for specifications).
12. 12

    Thermal imaging inspection (if equipped)
    If thermal camera is available and vehicle can be safely energized under controlled conditions, compare thermal signatures of HV cables during light load operation. Significant temperature variations between cables or hot spots on individual cables indicate high resistance connections or internal cable damage. This step requires HV system reactivation and should only be performed by qualified personnel with appropriate safety protocols.
13. 13

    Document and evaluate findings
    Review all inspection findings, photographs, and test data. Compare insulation resistance values to service specifications. Determine if any findings require immediate repair, future monitoring, or are within acceptable limits. Generate inspection report documenting cable condition, test results, and any recommendations. Any damage to HV cable insulation, connectors showing arcing, or failed insulation resistance tests require cable replacement or professional evaluation before returning vehicle to service.

Reassembly

1. Reinstall any protective shields, cable covers, or undertray panels removed for inspection access
2. Verify all HV connector safety covers and shields are properly reinstalled
3. If HV service disconnect was removed, reinstall service plug ensuring proper engagement and lock
4. Remove lockout/tagout devices
5. Lower vehicle from lift if raised
6. Using diagnostic tool, clear service mode and command HV system to ready state
7. Verify HV system activates normally with no new fault codes

Verification

• Connect diagnostic tool and verify no HV isolation faults or insulation resistance faults are present
• Verify HV system can achieve READY state without errors
• Check that battery voltage reaches normal operating voltage (typically 350-420V depending on state of charge)
• Confirm all high voltage warning indicators on instrument cluster function normally
• Perform test drive if no issues found, monitoring for any new warning messages or unusual behavior
• Verify insulation resistance values documented meet or exceed minimum specification (>100 megohms)
• Ensure all inspection documentation is completed and filed, including photographs of any concerns
• If any damage was found, vehicle should NOT be returned to service until repairs are completed by qualified technician

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