High Voltage Wiring Harness

Replacement of the high voltage wiring harness that connects the battery pack to the drive units, on-board charger, and other high voltage components in the Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• High voltage wiring harness assembly × 1 — Use OEM specification - Rivian part number specific to EDV 500
• HV connector seals/boots (if not included with harness) × 1 — Use OEM specification
• Cable ties and routing clips × 1 — Use OEM specification
• High voltage warning labels × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface with parking brake engaged and wheels chocked
2. Ensure 12V battery is fully charged (high voltage system operations will drain 12V battery)
3. Place high voltage service warning tags on steering wheel and service disconnect location
4. Put on all required personal protective equipment including Class 00 high voltage gloves, face shield, and insulated footwear
5. Access the 12V battery located in the driver's side chassis rail and disconnect negative terminal first, then positive terminal
6. Wait 5 minutes for vehicle systems to power down completely
7. Raise vehicle on lift or support safely on jack stands at manufacturer-specified lift points
8. Remove underbody splash shields and protective panels to access battery pack and motor compartments
9. Take comprehensive photographs of all high voltage harness routing, retention clips, and connector positions

Procedure

1. 1

   Locate and remove high voltage service disconnect
   The service disconnect is located on the front of the high voltage battery pack, accessible from underneath the vehicle. Using the Rivian service disconnect tool, rotate the orange service disconnect counterclockwise and pull straight out to remove. Place disconnect in a secure location away from the vehicle. Verify the orange handle is fully extracted and place high voltage warning tag on it.
   ⚠️Service disconnect must be removed and stored in technician's possession to prevent accidental reconnection during service.
2. 2

   Wait and verify capacitor discharge
   Wait minimum 15 minutes after service disconnect removal to allow high voltage system capacitors to discharge. Start timer when disconnect is fully removed. Do not proceed until full time has elapsed. After wait period, don high voltage insulated gloves and verify they are in good condition with no tears or damage.
   ⚠️15-minute wait is MANDATORY. Capacitors in drive units and DC-DC converter retain lethal voltage. Rushing this step can result in electrocution.
3. 3

   Verify zero high voltage at all connection points
   Using CAT III rated high voltage meter, verify 0V DC between HV+ and HV- at the battery pack main terminals, at both front and rear drive unit connections, and at the onboard charger connections. Test meter on known voltage source first to confirm meter operation. Document all voltage readings. Only proceed if all readings are below 5V DC.
   ⚠️If any voltage above 5V DC is detected, do not proceed. Reconnect service disconnect, consult Rivian technical support, and investigate fault in discharge circuit.
4. 4

   Disconnect battery pack high voltage connectors
   While wearing high voltage gloves, locate the orange high voltage positive and negative connectors at the battery pack output. Release the connector locking tabs by pressing or sliding per connector design. Pull connectors straight out without twisting. Immediately cover exposed high voltage terminals with insulating caps or tape. Secure disconnected cables away from battery terminals.
   ⚠Do not force connectors. If binding occurs, verify locking mechanism is fully released. Damaged connectors must be replaced.
5. 5

   Disconnect rear drive unit high voltage connectors
   Access the rear drive unit from underneath the vehicle. Locate the three-phase motor cable connector (orange) and release the safety lock. Disconnect the high voltage connector by pulling the release collar and separating the connector halves. Cap or insulate all exposed terminals. Disconnect any auxiliary connectors for temperature sensors or position sensors on the harness.
   ℹ️Rear drive unit connector requires specific pulling technique. Pull on connector body only, never on cables.
6. 6

   Disconnect front drive unit high voltage connectors
   Move to front drive unit location. Release and disconnect the three-phase motor cable connector using same procedure as rear unit. The front unit may have additional connections depending on EDV 500 configuration. Disconnect onboard charger high voltage input connector if routed through this harness section. Cap all exposed terminals.
7. 7

   Disconnect DC-DC converter and auxiliary high voltage connections
   Locate the DC-DC converter module (converts high voltage to 12V for vehicle systems). Disconnect the high voltage input connector from the harness. Disconnect any connections to the battery heater, battery thermal management system, or other high voltage accessories. Document each connection location and orientation.
8. 8

   Release harness routing clips and fasteners
   Working from battery pack toward drive units, release all cable routing clips, P-clips, and fasteners securing the high voltage harness to the vehicle chassis and underbody. Note exact position of each clip for reinstallation. Cut and remove cable ties as necessary. Keep harness supported to prevent strain on remaining connections.
   ⚠Do not allow harness to drop or hang unsupported. Weight of harness can damage remaining connections.
9. 9

   Remove harness through-cabin penetrations if applicable
   If high voltage harness routes through passenger compartment (for front power distribution), remove interior trim panels to access harness path. Release grommets and seals where harness penetrates bulkheads. Note orientation and sealing method for reassembly. Support harness from both sides during removal.
10. 10

    Remove complete high voltage harness assembly
    With all connections and fasteners released, carefully remove the entire high voltage harness assembly from the vehicle. Two technicians may be required due to harness length and weight. Inspect harness routing path for any damage, sharp edges, or debris. Clean mounting surfaces and inspect all connector receptacles remaining on vehicle for damage or contamination.
11. 11

    Inspect and prepare new harness
    Unpack new high voltage harness and verify part number matches vehicle specification. Inspect all connectors for damage, contamination, or missing seals. Apply thin coat of dielectric grease to connector seals and mating surfaces per manufacturer specification. Lay out new harness to match old harness configuration and verify all branches and lengths are correct.
    ⚠Do not use petroleum-based lubricants on high voltage connectors. Use only specified dielectric grease or approved silicone compound.
12. 12

    Route new harness through vehicle
    Following documented routing from removal, guide new harness through vehicle chassis and mounting points. Ensure harness follows same path as original with proper clearance from moving parts, heat sources, and sharp edges. Install through-bulkhead grommets and seals ensuring proper orientation and weathertight seal. Do not connect any high voltage connections yet.
    ⚠Verify minimum 50mm clearance from any moving suspension or drivetrain components throughout full suspension travel.
13. 13

    Install harness routing clips and fasteners
    Install all cable routing clips, P-clips, and fasteners to secure harness to chassis. Follow documented positions from removal. Ensure harness is supported at intervals not exceeding 300mm. Use new cable ties to secure harness at specified points. Avoid over-tightening cable ties which can damage harness insulation. Verify no stress or tension on harness at any connection point.
14. 14

    Connect front drive unit high voltage connections
    Remove insulating caps from front drive unit connectors. Inspect connector pins and sockets for damage or contamination. Align and connect three-phase motor cable connector ensuring proper orientation. Push connector together until locking mechanism fully engages with audible click. Verify connector is fully seated and lock is engaged. Connect onboard charger connection if applicable. Connect any auxiliary sensor connections.
    ⚠Connectors must be fully seated. Partial connection will cause arcing, overheating, and potential fire when energized.
15. 15

    Connect rear drive unit high voltage connections
    Remove insulating caps from rear drive unit connectors. Inspect and clean if necessary. Connect three-phase motor cable connector ensuring proper alignment and full engagement of locking mechanism. Verify security of connection. Connect auxiliary sensor connectors. Apply weatherproofing boots or covers if specified.
16. 16

    Connect DC-DC converter and auxiliary connections
    Connect high voltage input to DC-DC converter module ensuring full connector engagement. Connect battery thermal management connections and battery heater connections if equipped. Verify all connections are fully seated and locked. Apply connector seals or covers where specified.
17. 17

    Connect battery pack high voltage connectors
    Remove insulating caps from battery pack terminal connectors. Inspect terminals for any damage or contamination. Connect HV positive and HV negative connectors to battery pack terminals ensuring correct polarity. Push connectors fully onto terminals until locking mechanism engages. Verify both connections are fully seated and mechanically secure. Double-check polarity is correct.
    ⚠️Reversed polarity will cause catastrophic failure of power electronics and potential fire when system is energized. Verify polarity markings on connectors and terminals match.
18. 18

    Perform visual inspection of all connections
    Systematically inspect every high voltage connection point to verify full engagement, proper locking, and correct routing. Verify no connectors show gaps between mating surfaces. Check that all weather seals and boots are properly positioned. Confirm harness has proper clearance from all moving parts, hot surfaces, and sharp edges throughout its routing. Verify all routing clips are installed and secure.
19. 19

    Install underbody panels and shields
    Reinstall all underbody splash shields and protective panels removed during access. Ensure all fasteners are installed and properly torqued. Verify panels do not contact or create pressure points on high voltage harness. Apply new high voltage warning labels where original labels were removed or damaged.
20. 20

    Reconnect 12V battery
    Lower vehicle if raised. Reconnect 12V battery positive terminal first, then negative terminal. Do not reinstall high voltage service disconnect yet. Vehicle control systems will power up but high voltage system will remain disabled.

Reassembly

1. Before installing high voltage service disconnect, perform comprehensive pre-energization inspection of all work performed
2. Verify all high voltage connectors are fully engaged and mechanically secure with no visible gaps
3. Confirm all harness routing clips, fasteners, and cable ties are properly installed
4. Verify all underbody panels and shields are reinstalled and do not contact harness
5. Ensure all personnel and tools are clear of high voltage system before energization
6. Remove all high voltage warning tags from vehicle and service disconnect

Verification

• With all personnel clear of vehicle and wearing appropriate PPE, install high voltage service disconnect by inserting straight in and rotating clockwise until fully seated
• Using Rivian diagnostic system, perform high voltage system initialization and verify no high voltage isolation faults are present
• Check for diagnostic trouble codes related to high voltage system, drive units, onboard charger, or DC-DC converter
• Verify high voltage battery pack voltage is present and within normal range (typically 650-800V depending on state of charge)
• Perform high voltage insulation resistance test using Rivian diagnostic tools - should show greater than 500 ohms per volt minimum
• Command each drive unit to operate using diagnostic system and verify both motors respond without faults
• Verify onboard charger communication and function by initiating charge session
• Verify DC-DC converter operation by confirming 12V system voltage in normal range (13.5-14.5V) with high voltage system active
• Test drive vehicle in controlled environment to verify normal propulsion, regenerative braking, and no warning messages
• Perform final inspection of harness routing while vehicle is running - verify no contact with moving parts or heat sources
• Use thermal imaging camera if available to verify no hot spots on connections during operation
• Document all testing performed and results in vehicle service records

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