This procedure covers the removal and replacement of the negative battery cable on the 2025 Rivian EDV 500 dual motor electric delivery van, including high-voltage system lockout and safety protocols.

Warnings

Tools required

Parts

• Negative battery cable × 1 — Use OEM specification
• Cable terminal bolts (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and chock all four wheels with mechanical wheel chocks
2. Verify vehicle is in Park and ignition is OFF with key fob at least 15 feet away from vehicle
3. Open driver's door to prevent lockout and disable automatic locking
4. Locate and review high-voltage component locations in service manual
5. Don high-voltage insulated gloves and safety equipment
6. Document any stored fault codes using diagnostic scanner before disconnecting power

Procedure

1. 1

   Access high-voltage service disconnect
   Open the rear cargo area. Remove the left-side rear floor panel by releasing the four quarter-turn fasteners. Locate the high-voltage service disconnect plug beneath the floor panel near the battery pack.
2. 2

   Disconnect high-voltage system
   While wearing insulated gloves, rotate the high-voltage service disconnect lever counterclockwise 90 degrees. Pull the orange service disconnect plug straight out from the receptacle. Place lockout/tagout device on the disconnect to prevent reconnection. Verify the orange interlock loop is intact.
   ⚠️Do not proceed until high-voltage disconnect is removed and locked out. The disconnect controls power to all high-voltage systems.
3. 3

   Wait for capacitor discharge
   Wait a minimum of 5 minutes with the high-voltage disconnect removed to allow all high-voltage capacitors in the system to fully discharge. Do not touch any orange high-voltage cables during this time.
4. 4

   Verify system is de-energized
   Using a high-voltage capable multimeter, verify zero voltage at the high-voltage battery terminals by probing the exposed contacts in the service disconnect receptacle. Reading should be 0-5V DC or less. If voltage is present, wait additional time and retest.
5. 5

   Access 12V battery compartment
   Open the front hood. Locate the 12V lithium auxiliary battery in the front right corner of the engine compartment. Remove the battery cover by releasing the two clips on the front edge and lifting up and forward.
6. 6

   Disconnect negative cable at battery
   Using a 10mm socket, loosen the negative battery terminal bolt at the 12V battery. The negative terminal is marked with a minus (-) symbol and black cable. Remove the cable from the terminal and secure it away from the battery post using a non-conductive tie or tape.
7. 7

   Trace and disconnect cable at frame ground
   Follow the negative cable from the battery to its ground point on the left front frame rail. Using a 13mm socket, remove the ground bolt securing the cable lug to the frame. Note the exact mounting location and any additional ground straps sharing the same connection point.
8. 8

   Remove cable routing clips
   Release all cable routing clips and ties securing the negative cable along its path from battery to frame ground. Note the exact routing path and clip locations for reinstallation. Remove any protective loom or conduit covering the cable.
9. 9

   Remove old negative cable
   Carefully remove the negative battery cable from the vehicle, ensuring no damage to surrounding components or wiring. Inspect the cable routing path for any sharp edges or wear points that may have damaged the old cable.
10. 10

    Prepare new cable and connection points
    Inspect the new negative battery cable to ensure it matches the original. Clean the frame ground mounting point with a wire brush to bare metal for optimal conductivity. Clean the battery terminal post with a battery terminal brush. Apply a thin coat of dielectric grease to the terminal post.
11. 11

    Route and install new cable
    Route the new negative cable along the original path from frame ground to battery, ensuring proper clearance from moving parts, heat sources, and sharp edges. Secure the cable in all original routing clips and reinstall any protective loom or conduit.
12. 12

    Connect cable at frame ground
    Position the negative cable lug onto the frame ground point, ensuring metal-to-metal contact with the cleaned mounting surface. Reinstall any additional ground straps in their original positions. Install and tighten the 13mm ground bolt securely. Torque specifications are not available in database; tighten firmly but do not overtighten to avoid stripping threads.
13. 13

    Connect cable at battery terminal
    Place the negative cable terminal onto the negative battery post, ensuring it seats fully. Install the 10mm terminal bolt and tighten securely. Apply dielectric grease over the completed connection to prevent corrosion. Reinstall the battery cover.
14. 14

    Reconnect high-voltage system
    Return to the rear cargo area. Remove the lockout/tagout device from the high-voltage service disconnect. While wearing insulated gloves, insert the orange service disconnect plug fully into the receptacle until it seats completely. Rotate the service disconnect lever clockwise 90 degrees to lock. Verify the connection is secure.
15. 15

    Reinstall panels and test system
    Reinstall the rear floor panel and secure with the four quarter-turn fasteners. Close the rear cargo area and front hood. Place the key fob in the vehicle and press the brake pedal to wake the vehicle systems. Verify the instrument cluster illuminates normally without high-voltage system warnings.

Reassembly

1. Ensure all battery covers and floor panels are properly reinstalled and secured
2. Verify negative cable is properly routed and secured in all original clips with no tension or rubbing
3. Confirm high-voltage service disconnect is fully engaged and locked
4. Remove wheel chocks only after verifying parking brake function

Verification

• Turn on vehicle ignition and verify all systems power up normally without warning lights related to battery or high-voltage system
• Check for proper operation of electric parking brake and verify it holds vehicle on incline
• Use diagnostic scanner to verify no new fault codes related to battery or ground circuits
• Verify all chassis ground-dependent systems function correctly including lights, HVAC, and infotainment
• Test drive vehicle and confirm normal operation of all electrical systems and regenerative braking
• Inspect negative cable connections after test drive to ensure no looseness, heat, or discoloration at terminals

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