High Voltage Service Disconnect

This procedure safely disconnects the high voltage battery system on the 2025 Rivian EDV 500, isolating all high voltage components to allow safe service work on the electric drivetrain and related systems.

Warnings

Tools required

Parts

• High voltage service disconnect plug protective cap × 1 — Use OEM specification
• High voltage interlock loop connector × 1 — Use OEM specification

Preparation

1. Verify technician has valid high voltage electrical safety certification and training on Rivian EDV platform
2. Ensure vehicle is parked on level ground in a dry, well-ventilated area away from flammable materials
3. Confirm vehicle is in Park mode and parking brake is fully engaged
4. Remove all metal jewelry, watches, and conductive accessories from your person
5. Inspect Class 0 insulated gloves for any cuts, tears, or damage. Do not use if damaged
6. Have a second trained person present who knows emergency shutdown procedures
7. Verify fire extinguisher rated for electrical fires (Class C) is readily accessible
8. Place wheel chocks front and rear of all tires
9. Document pre-service state of vehicle systems and take photos of high voltage component locations

Procedure

1. 1

   Power down vehicle completely
   Ensure the vehicle is fully powered down by pressing and holding the power button until all dash displays go dark. Wait 30 seconds after displays are off. Verify no status lights remain illuminated on the charging port or dash. Open driver door and leave open to prevent vehicle from attempting to power on.
   ⚠Do not proceed if vehicle attempts to power back on or shows any active systems
2. 2

   Disconnect 12V auxiliary battery
   Open the front hood. Locate the 12V auxiliary battery in the front compartment. Using appropriate tools, disconnect the negative (-) terminal first, then the positive (+) terminal. Isolate terminals to prevent accidental reconnection. Wait 5 minutes for all control modules to fully power down.
   ⚠Always disconnect negative terminal first to prevent short circuits
3. 3

   Install lockout/tagout device
   Attach a lockout/tagout tag to the 12V battery area indicating high voltage service in progress. Record your name, date, and time on the tag. This prevents anyone from reconnecting power during service. Keep the key to the lockout device on your person at all times.
   ⚠️Never bypass lockout/tagout procedures. Unauthorized reconnection during service can be fatal
4. 4

   Don high voltage personal protective equipment
   Put on Class 0 insulated gloves ensuring they fully cover wrists and have no damage. Wear safety glasses with side shields. Put on dielectric overshoes if available. Verify all PPE is rated for minimum 1000V DC and is within certification date.
   ⚠️Do not proceed without proper high voltage PPE. Standard work gloves offer NO protection against high voltage
5. 5

   Access high voltage service disconnect location
   For the Rivian EDV 500, the high voltage service disconnect is located in the battery pack assembly underneath the vehicle cargo area. Remove the interior cargo floor panels to access the service disconnect cover. Remove the protective cover by unfastening the T30 Torx fasteners (typically 4-6 fasteners). Set cover and fasteners aside in clean area.
   ℹ️Service disconnect location may vary by EDV configuration. Consult Rivian service manual for exact location if not found as described
6. 6

   Verify high voltage warning labels
   Confirm you can see the orange high voltage warning labels around the service disconnect area. Verify all orange-colored cables and connectors are clearly visible. If any components appear damaged, corroded, or show signs of arcing, do not proceed and consult Rivian technical support immediately.
7. 7

   Disconnect high voltage interlock loop
   Locate the high voltage interlock loop connector (small orange connector near service disconnect). While wearing insulated gloves, carefully disconnect this connector by pressing the release tab and pulling straight out. This breaks the interlock circuit and signals the battery management system that service is being performed.
   ⚠The interlock loop is a low voltage circuit but must be disconnected before handling the main service disconnect
8. 8

   Remove high voltage service disconnect plug
   Identify the main high voltage service disconnect plug (orange handled T-grip or lever). Rotate the disconnect handle counterclockwise 90 degrees until it stops. Pull the disconnect plug straight up and out with steady force. The disconnect physically separates the battery pack from all high voltage systems. Place the disconnect plug in a secure location away from the vehicle.
   ⚠️Do not touch any exposed contacts on the service disconnect plug or receptacle. High voltage may still be present
9. 9

   Install safety cap on disconnect receptacle
   Immediately install the protective safety cap over the exposed high voltage disconnect receptacle in the battery pack. This prevents accidental contact with energized contacts and foreign object intrusion. Ensure cap is fully seated and secure.
   ⚠️Never leave the disconnect receptacle uncovered. Exposed contacts may remain energized
10. 10

    Wait for capacitor discharge period
    Wait a minimum of 10 minutes after removing the service disconnect plug. This allows high voltage capacitors throughout the system to discharge to safe levels. Set a timer to ensure full wait time. Do not touch any high voltage components during this period.
    ⚠️Capacitors can store lethal voltage even after disconnect. The 10-minute wait is mandatory, not optional
11. 11

    Verify zero voltage on high voltage bus
    Using a calibrated high voltage multimeter or voltage detector rated for minimum 1000V DC, carefully test for voltage at accessible high voltage test points (typically marked near the disconnect area). With meter set to DC voltage, verify reading is below 5V DC. Test multiple points if accessible. Document voltage readings.
    ⚠️If voltage reading is above 5V DC, wait an additional 10 minutes and retest. Do not proceed with service if voltage remains present
12. 12

    Verify orange cable isolation
    Visually inspect all visible orange high voltage cables to confirm they are not damaged, pinched, or in contact with sharp edges. Verify no orange cables are routed near areas where you will be working. If your service work requires accessing areas near orange cables, maintain minimum 6-inch clearance at all times.
    ⚠️Never cut, modify, or remove orange high voltage cables unless specifically required and trained for that procedure
13. 13

    Document high voltage isolation
    Take photos of the disconnected service plug, installed safety cap, and lockout/tagout tag. Record the time of disconnect, voltage measurements taken, and technician name in service documentation. This creates a safety record and ensures proper reconnection procedures are followed.
    ℹ️Documentation is required for warranty work and legal protection

Reassembly

1. Before reconnection, verify all service work is complete and all tools have been removed from vehicle
2. Inspect service disconnect plug contacts for any damage, corrosion, or foreign material. Clean with approved electrical contact cleaner if needed
3. Remove safety cap from battery pack disconnect receptacle
4. Align service disconnect plug with receptacle ensuring proper orientation (keyed connector)
5. Insert disconnect plug straight down until fully seated, then rotate handle clockwise 90 degrees to locked position
6. Reconnect high voltage interlock loop connector until it clicks into place
7. Reinstall service disconnect cover and secure with all T30 Torx fasteners
8. Reinstall interior cargo floor panels
9. Reconnect 12V auxiliary battery: positive (+) terminal first, then negative (-) terminal
10. Remove lockout/tagout device and tag
11. Close all vehicle doors and hood

Verification

• Power on the vehicle and verify all systems initialize normally without high voltage faults
• Check instrument cluster for any warning lights related to high voltage system. Some informational messages may appear initially but should clear
• Using Rivian diagnostic software if available, verify battery management system shows normal status and all high voltage contactors are functioning
• Perform a low-speed test drive to confirm both motors engage properly and AWD system functions normally
• Verify regenerative braking functions correctly by testing gentle deceleration
• Check that vehicle charges normally if charging equipment is available
• Document all verification steps and clear any temporary fault codes that may have been set during disconnect procedure
• If any warnings persist or vehicle does not operate normally, repeat voltage verification and ensure service disconnect is fully seated and locked

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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