This procedure covers the inspection, cleaning, and replacement of the high-voltage battery terminals on the 2025 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• High-voltage battery terminal set × 1 — Use OEM specification
• Terminal bolt set × 1 — Use OEM specification
• High-voltage warning labels × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place safety cones around vehicle and implement lockout/tagout procedures
3. Ensure all personnel are clear that high-voltage work is being performed
4. Allow battery pack to cool for minimum 30 minutes after vehicle was last operated
5. Put on high-voltage insulated gloves and verify they are free from damage or holes
6. Disconnect 12V auxiliary battery negative terminal
7. Remove driver's seat to access battery disconnect location under vehicle floor

Procedure

1. 1

   Access Battery Compartment
   Remove the underbody access panels to reach the high-voltage battery pack. Remove the plastic clips and fasteners securing the forward battery access panel. Store all fasteners in a labeled container.
2. 2

   Disable High-Voltage System
   Locate the manual service disconnect (MSD) under the front battery access area. Rotate the MSD counterclockwise and pull to remove. Store the MSD in a secure location away from the vehicle to prevent accidental reconnection. Wait 5 minutes for capacitors to discharge.
3. 3

   Verify System De-Energization
   Using the high-voltage capable multimeter with insulated probes, verify voltage across the main battery terminals reads 0V DC. Test multiple terminal pairs to ensure complete discharge. Document voltage readings. If any voltage is present, do not proceed.
4. 4

   Remove Battery Pack Cover
   Remove the fasteners securing the battery pack top cover. Carefully lift the cover away, being mindful of any remaining wire harness connections. Set cover aside on a clean, protected surface.
5. 5

   Document Terminal Configuration
   Take clear photographs of the terminal connections, wire routing, and any identification labels before disassembly. Note the orientation and position of each terminal connection for proper reassembly.
6. 6

   Remove High-Voltage Connectors
   Locate the orange high-voltage connectors at the battery terminals. Press the locking tabs and carefully disconnect each connector. Support the connectors to prevent strain on the wiring harness.
7. 7

   Remove Terminal Bolts
   Using the insulated socket set, remove the bolts securing the battery terminals to the battery posts. Loosen bolts in a crossing pattern to prevent binding. Keep positive and negative terminal hardware separated and labeled.
8. 8

   Remove Battery Terminals
   Carefully remove the terminal clamps from the battery posts. If terminals are corroded or stuck, use the battery terminal puller tool. Do not pry or use excessive force that could damage the battery posts.
9. 9

   Inspect and Clean Contact Surfaces
   Inspect battery posts and terminals for corrosion, damage, or pitting. Clean posts with wire brush or terminal cleaning tool until bright metal is visible. Inspect for cracks or deformation that would require battery pack service.
10. 10

    Install New or Cleaned Terminals
    Apply a thin coat of anti-corrosion spray to battery posts. Position new or cleaned terminals onto posts, ensuring correct polarity (positive and negative). Verify terminals seat fully onto posts without gaps.
11. 11

    Install Terminal Bolts
    Thread terminal bolts by hand first to ensure proper engagement. Tighten bolts in a crossing pattern using the insulated torque wrench. Note: Specific torque values should be obtained from Rivian service documentation as none are provided in the database.
12. 12

    Reconnect High-Voltage Connectors
    Reconnect the orange high-voltage connectors to the terminals, ensuring they click fully into place. Verify locking tabs are engaged. Apply dielectric grease to connector seals if specified by manufacturer.
13. 13

    Reinstall Battery Pack Cover
    Position the battery pack cover, aligning all mounting points. Install and tighten all fasteners in a crossing pattern. Ensure cover gasket or seal is properly positioned to maintain weatherproofing.
14. 14

    Reinstall Underbody Panels
    Reinstall the underbody access panels, ensuring all clips and fasteners are properly secured. Verify panels are flush and properly aligned.
15. 15

    Re-Enable High-Voltage System
    Reinstall the manual service disconnect (MSD) by inserting and rotating clockwise until fully seated. Verify it is locked in position. Reconnect the 12V auxiliary battery negative terminal.

Reassembly

1. Reinstall driver's seat and any interior panels removed for access
2. Verify all underbody panels are secure and properly fastened
3. Ensure no tools or parts remain in battery compartment or under vehicle
4. Remove lockout/tagout devices only after all reassembly is complete

Verification

• Connect Rivian diagnostic tool and clear any stored fault codes related to high-voltage system isolation
• Perform high-voltage system integrity check using diagnostic tool
• Verify battery management system recognizes proper terminal connections
• Start vehicle and verify all high-voltage warnings clear from instrument cluster
• Test vehicle in forward and reverse to confirm motor operation
• Perform a brief test drive to verify normal operation and battery charging function
• Re-scan for fault codes and verify no new high-voltage related codes are present
• Verify battery state of charge display is functioning correctly

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