Battery Cable - Positive

This procedure covers the removal and replacement of the high-voltage positive battery cable on the 2025 Rivian EDV 500 dual motor AWD electric delivery vehicle.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification
• Cable retention clips × 4 — Use OEM specification
• High-voltage warning labels × 1 — Replace if damaged

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is powered off and key fob is at least 20 feet away from vehicle
3. Place high-voltage warning signs around vehicle work area
4. Don high-voltage insulated gloves and arc-rated face shield
5. Remove cargo area floor panels to access battery compartment
6. Connect diagnostic tool and verify no active high-voltage faults
7. Document battery state of charge (should be below 30% for this procedure)
8. Take photos of cable routing and connector orientations before disassembly

Procedure

1. 1

   Disable high-voltage system
   Using the diagnostic tool, initiate the high-voltage system shutdown procedure. Navigate to 'Service Mode' menu and select 'HV System Isolation'. Confirm that the system reports 'HV System Safe' status. Verify that the instrument cluster displays 'Service Mode Active' and orange high-voltage indicator is off.
2. 2

   Remove HV service disconnect
   Locate the high-voltage service disconnect (orange handle) on top of the battery pack. Pull the service disconnect straight up and out of its receptacle. Store the disconnect in a secure location away from the vehicle. This physically disconnects the battery pack into two isolated sections.
3. 3

   Wait for capacitor discharge
   Wait minimum 15 minutes to allow all high-voltage capacitors in the system to fully discharge. Set a timer and do not proceed until full time has elapsed. During this time, keep the work area clear and maintain barrier protection.
4. 4

   Verify zero voltage
   Using a high-voltage capable multimeter, verify zero voltage across the positive and negative battery terminals. Test at the service disconnect location and at the motor inverter connections. All readings must show less than 5 volts DC. If voltage is present, do not proceed and investigate cause. Re-verify the service disconnect is removed and wait additional time.
5. 5

   Remove underbody shield
   Remove the composite underbody shield panels beneath the battery pack area. Remove all perimeter fasteners and carefully lower panels. This provides access to the positive cable routing from the battery pack forward to the motor inverters.
6. 6

   Disconnect positive cable at front motor inverter
   Locate the positive cable connection at the front motor inverter unit. Remove the orange protective cover from the high-voltage connector. Depress the connector lock tab and carefully pull the connector straight off. Inspect the connector seals for damage and note orientation for reinstallation. Cap the inverter terminal with protective covering.
7. 7

   Disconnect positive cable at rear motor inverter
   Locate the positive cable connection at the rear motor inverter unit. Remove the orange protective cover. Release the connector lock mechanism and disconnect the positive cable. The EDV 500 uses a dual motor configuration with separate cables to each inverter. Inspect seals and cap the exposed terminal.
8. 8

   Release cable retention points
   Working from front to rear, release all cable retention clips and brackets securing the positive cable along its routing path. There are approximately 8-10 retention points along the battery pack sides and under-floor area. Note the exact position of each clip for reinstallation. Cut and remove any cable ties, keeping track of locations.
9. 9

   Disconnect positive cable at battery pack
   At the battery pack positive terminal location, remove the terminal access cover. Remove the cable terminal bolts securing the positive cable to the battery pack positive bus bar. Carefully lift the cable terminal away from the bus bar. Ensure no tools or conductive materials contact the negative terminal or pack housing during removal.
10. 10

    Remove positive cable assembly
    Carefully route the positive cable assembly out of the vehicle, following the original cable path in reverse. The cable is heavy and may require assistance. Check that all retention points have been released. Avoid bending the cable excessively or allowing it to contact sharp edges. Place the old cable on a clean, non-conductive surface for comparison with new cable.
11. 11

    Inspect cable routing path
    Thoroughly inspect the cable routing path for any damage, debris, or moisture. Check all mounting brackets and clips for cracks or deformation. Clean the battery pack terminal area with isopropyl alcohol. Verify that protective cable routing channels and grommets are intact. Replace any damaged components before installing new cable.
12. 12

    Install new positive cable assembly
    Route the new positive cable through the vehicle following the exact path of the original cable. Reference photos taken during disassembly. Ensure the cable does not contact any sharp edges, moving components, or sources of heat. Position the cable with proper orientation at each connection point before securing.
13. 13

    Connect cable at battery pack
    Install new terminal seals on the battery pack connection point. Position the positive cable terminal onto the battery pack positive bus bar, ensuring full contact and correct orientation. Install terminal bolts and tighten evenly in a cross pattern. Without torque specifications available, tighten securely but do not over-torque aluminum terminals. Apply appropriate torque sealant if specified by service manual.
14. 14

    Secure cable retention points
    Working from the battery pack forward, secure the positive cable at all retention points. Install new retention clips in their original positions. Ensure the cable has adequate slack for thermal expansion but is not loose enough to vibrate. Install new cable ties at documented locations. Verify cable clearance from all moving parts and potential pinch points.
15. 15

    Connect cable at motor inverters
    Install new seals on both front and rear motor inverter connectors. Connect the positive cable to each inverter, ensuring connectors are fully seated and lock mechanisms engage with an audible click. Verify connector orientation matches documented positions. Install orange protective covers over each high-voltage connection point. Apply any required high-voltage warning labels.

Reassembly

1. Reinstall underbody shield panels with all original fasteners
2. Perform a final visual inspection of all high-voltage connections and cable routing
3. Verify all protective covers and orange high-voltage shields are installed
4. Reinstall cargo area floor panels and interior trim components
5. Ensure no tools or materials are left in the high-voltage compartment areas

Verification

• With high-voltage gloves still on, use multimeter to verify proper continuity through the positive cable from battery pack to each inverter (service disconnect still removed)
• Check for any signs of damage, improper routing, or missing hardware through visual inspection
• Reinstall the high-voltage service disconnect, pressing firmly until it clicks into place
• Exit service mode using diagnostic tool and allow system to re-energize
• Verify high-voltage system initializes without faults on instrument cluster
• Check diagnostic tool for any newly set high-voltage system fault codes
• Perform a stationary drive motor rotation test using diagnostic tool to verify proper inverter operation
• Test drive vehicle at low speed in a safe area to confirm normal operation and no warning lights
• Re-scan for fault codes after test drive and verify no issues present
• Document repair with photos and update vehicle service records

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