This procedure covers the removal and replacement of the engine bay fuse box on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box mounting hardware kit × 1 — Use OEM specification
• Weather seal gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Power off the vehicle completely using the main power button
3. Open the front hood and secure with prop rod
4. Locate and disconnect the 12V battery negative terminal, then positive terminal
5. Wait minimum 10 minutes for high-voltage system capacitors to discharge
6. Take detailed photographs of all wiring harness connections to the fuse box from multiple angles
7. Document all fuse positions and ratings if reusing fuses
8. Cover front fenders with protective material to prevent damage

Procedure

1. 1

   Remove engine bay cover panels
   Using trim panel removal tools, carefully pry up the plastic engine bay cover panels that conceal the fuse box area. Start from the rear edge and work forward. Remove the six T25 Torx fasteners securing the main cover panel. Lift the panel up and away from the bay, disconnecting any electrical connectors for under-hood lighting if present.
2. 2

   Disconnect fuse box cover
   Release the four locking tabs on the fuse box cover by pressing down and pulling outward simultaneously. Lift the cover straight up to expose the fuses and relays. Remove and store the cover in a clean, dry location. Inspect the underside of the cover for any corrosion or moisture damage.
3. 3

   Document and remove fuses and relays
   Using your phone or camera, photograph the exact position of all fuses and relays. Using the appropriate fuse puller tool (located inside the fuse box), remove all fuses and relays. Place them in a labeled container maintaining their original positions. Inspect each fuse for blown elements or corrosion.
4. 4

   Disconnect primary wiring harnesses
   Locate the four main wiring harness connectors on the bottom and sides of the fuse box. Each connector has a colored release tab (red or gray). Press the release tab while pulling the connector straight out with firm, even pressure. Work on one connector at a time, comparing with reference photos. Label each connector with masking tape if needed.
5. 5

   Disconnect secondary and ground connections
   Identify the three smaller secondary connectors and two ground straps attached to the fuse box. Remove ground strap fasteners using a 10mm socket. For secondary connectors, press the locking tabs and pull straight back. Some connectors may have sliding locks that need to be pushed forward before disconnection is possible.
6. 6

   Remove fuse box mounting fasteners
   Locate the three 12mm mounting bolts securing the fuse box to the inner fender and firewall. Remove these bolts using a 12mm socket, supporting the fuse box weight with your other hand. Note that one bolt may be hidden beneath a wiring harness and requires moving the harness aside.
7. 7

   Remove two T30 Torx bracket fasteners
   At the rear of the fuse box, locate and remove two T30 Torx fasteners securing the support bracket to the firewall. These fasteners may be tight due to thread-locking compound. Apply steady pressure to avoid stripping the Torx heads.
8. 8

   Extract fuse box assembly
   Carefully lift the fuse box assembly up and toward the front of the vehicle at a 30-degree angle to clear mounting brackets. Guide wiring harnesses through their routing channels as you lift. The assembly should weigh approximately 8-10 pounds. Place the removed fuse box on a clean work surface.
9. 9

   Inspect mounting area and clean connections
   Examine the mounting surface on the firewall and inner fender for corrosion, cracks, or damage. Clean all mounting surfaces with a wire brush if corrosion is present. Inspect all wiring harness connectors for bent pins, corrosion, or damage. Clean connector terminals with electrical contact cleaner and allow to dry completely.
10. 10

    Install replacement weather seal
    Remove the old weather seal gasket from around the fuse box mounting area. Clean the sealing surface thoroughly. Position the new weather seal gasket ensuring proper alignment with mounting holes and drainage channels. Press firmly to seat the gasket completely.
11. 11

    Position new fuse box assembly
    Guide the new fuse box assembly into position at the same 30-degree angle used during removal, routing wiring harnesses through their channels. Align the mounting holes with the firewall and inner fender mounting points. Lower the assembly onto the mounting surface, ensuring the weather seal seats properly.
12. 12

    Install mounting hardware
    Thread in the three 12mm mounting bolts by hand to prevent cross-threading. Tighten bolts in a star pattern to ensure even seating. Install the two T30 Torx bracket fasteners at the rear and tighten firmly. Verify the fuse box is solidly mounted with no movement.
13. 13

    Reconnect all wiring harnesses
    Beginning with ground straps, reconnect and tighten the 10mm ground fasteners. Reconnect all wiring harness connectors in reverse order of removal, referring to your reference photos. Each connector should click audibly when fully seated. Verify all locking tabs have engaged properly by attempting to pull connectors apart gently.
14. 14

    Reinstall fuses and relays
    Using your photos and documentation, reinstall all fuses and relays in their original positions. Ensure each component is fully seated in its socket. Apply a small amount of dielectric grease to relay terminals if desired. Replace any blown fuses with exact same amperage rating.
15. 15

    Test electrical systems before final assembly
    Reconnect the 12V battery positive terminal, then negative terminal. Power on the vehicle and use a multimeter to verify proper voltage at the fuse box (should read approximately 12.6-14.4V depending on charge state). Check for any warning lights or error messages on the dashboard. Test basic electrical functions including lights, wipers, and climate control.

Reassembly

1. Reinstall the fuse box cover by aligning and pressing down until all four locking tabs engage
2. Reinstall engine bay cover panels in reverse order, ensuring all T25 Torx fasteners are tightened
3. Reconnect any under-hood lighting connectors
4. Verify all tools and parts have been removed from the engine bay
5. Close hood and verify proper latching

Verification

• Start the vehicle and verify normal operation with no warning lights
• Test all electrical systems including headlights, turn signals, brake lights, wipers, climate control, and power windows
• Use a diagnostic scanner to check for any fault codes related to the fuse box or electrical system
• Verify proper operation of drive motors and AWD system with a short test drive
• Check for any unusual sounds, smells, or electrical malfunctions
• Confirm all dashboard displays and touch screen systems function properly
• Inspect the fuse box area for any signs of moisture intrusion or loose connections after test drive

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