High Voltage Wiring Harness

This procedure covers the inspection, removal, and replacement of the high voltage wiring harness that connects the battery pack to the drive motors and charging system on the 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• High voltage wiring harness assembly × 1 — Use OEM specification
• HV connector seals and gaskets × 1 — Use OEM specification
• Cable tie kit × 1 — Use OEM specification
• High voltage warning labels × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been powered off for at least 5 minutes
3. Place high voltage warning signs around the work area and restrict access
4. Put on appropriate high voltage PPE including insulated gloves and safety glasses
5. Open rear cargo doors and access panel to battery compartment
6. Disconnect 12V auxiliary battery negative terminal and isolate the cable
7. Locate and remove the high voltage service disconnect plug from battery pack - store in your pocket to maintain lockout
8. Apply lockout/tagout procedures to service disconnect location
9. Wait minimum 15 minutes for high voltage system capacitors to discharge
10. Using diagnostic scan tool, verify high voltage system shows as de-energized
11. Raise and support vehicle on jack stands at manufacturer-specified lift points if undercarriage access is required
12. Remove necessary underbody panels to access HV routing path

Procedure

1. 1

   Verify system de-energization
   Using a calibrated high voltage multimeter, verify zero voltage between HV+ and HV- terminals at the battery pack main contactors. Verify zero voltage between HV+ and chassis ground, and HV- and chassis ground. Document all readings. If any voltage is detected, stop work immediately and investigate why the system has not discharged.
2. 2

   Disconnect HV harness at battery pack
   Locate the main high voltage harness connections at the battery pack output terminals. Release the orange safety locks on each connector by pulling the locking tab away from the connector body. Disconnect the HV+ (positive) and HV- (negative) main power cables from the battery pack. Inspect connector pins for damage, corrosion, or overheating. Cover exposed terminals with insulating caps immediately.
3. 3

   Disconnect front motor power connections
   Access the front drive unit compartment. Locate the three-phase power cable connections to the front motor inverter. Release the safety interlock connector first (small orange connector). Then release the locking mechanism on the main HV power connector and carefully disconnect it from the motor inverter unit. Inspect the connector seal and pins for any damage or contamination.
4. 4

   Disconnect rear motor power connections
   Access the rear drive unit compartment. Locate the three-phase power cable connections to the rear motor inverter. Release the safety interlock connector first. Then release the locking mechanism on the main HV power connector and disconnect it from the rear motor inverter unit. Check connector condition and seal integrity.
5. 5

   Disconnect DC fast charging connections
   Locate the high voltage DC fast charge port connections on the driver side of the vehicle. Release the interlock connector, then unlock and disconnect the HV charging harness from the charge port module. Cap the exposed terminals to prevent contamination.
6. 6

   Disconnect AC charging connections
   Access the onboard charger module location. Disconnect the high voltage AC input cables from the onboard charger by releasing the connector locks and carefully pulling the connectors straight out. Note the routing and orientation for reinstallation.
7. 7

   Release harness mounting points
   Systematically work along the entire length of the high voltage harness routing path, removing all mounting brackets, clips, and cable ties that secure the harness to the vehicle chassis. Take photos of the routing path for reference during reinstallation. Count and note the location of all mounting points.
8. 8

   Remove HV harness assembly
   Carefully remove the entire high voltage harness assembly from the vehicle, ensuring it does not snag on any sharp edges or components. Inspect the removed harness thoroughly for any signs of damage, including checking the orange insulation jacket for cuts, abrasions, heat damage, or discoloration. Check all connector boots for cracks or deterioration.
9. 9

   Inspect and prepare mounting locations
   Clean all harness mounting points, connector mounting surfaces, and routing channels. Remove any debris, corrosion, or damaged clips. Verify all grounding points are clean and free of corrosion. Replace any damaged mounting brackets or hardware.
10. 10

    Route new HV harness
    Carefully route the new high voltage harness assembly following the exact path documented during removal. Ensure the harness does not contact any sharp edges, moving components, or heat sources. Maintain proper clearances from all mechanical components and exhaust paths. Leave slight slack at connection points to prevent strain.
11. 11

    Secure harness mounting points
    Install all mounting brackets, clips, and support points in their original locations. Use new cable ties where applicable. Ensure the harness is properly supported along its entire length with no excessive tension or sagging sections. Verify minimum clearances are maintained from all rotating or moving parts.
12. 12

    Connect battery pack terminals
    Apply a thin layer of dielectric grease to connector seals if specified by manufacturer. Carefully align and connect the HV+ and HV- cables to the battery pack output terminals. Ensure connectors are fully seated - you should hear an audible click. Engage the orange safety locks on each connector until they snap into place. Verify connections are secure by gently pulling on the cables.
13. 13

    Connect motor inverter connections
    Connect the high voltage harness to both front and rear motor inverters. For each connection: align the connector carefully, push firmly until fully seated and an audible click is heard, engage the locking mechanism, then connect the safety interlock connector. Verify each connector seal is properly positioned and not pinched.
14. 14

    Connect charging system connections
    Reconnect the DC fast charge port harness and AC onboard charger connections. Ensure all connectors are fully seated and locked. Verify interlock connectors are properly engaged. Check that connector seals are in place and not damaged.
15. 15

    Perform insulation resistance test
    Before re-energizing the system, use an insulation resistance tester (megohmmeter) to verify harness insulation integrity. Test HV+ to ground, HV- to ground, and HV+ to HV-. All readings should exceed 500 megohms minimum. Record all measurements. If any reading is below specification, do not proceed - investigate the cause.

Reassembly

1. Reinstall all underbody panels and access covers removed during the procedure
2. Verify all high voltage connectors have safety locks properly engaged and interlock connectors are connected
3. Remove lockout/tagout devices
4. Reconnect the 12V auxiliary battery negative terminal
5. Install the high voltage service disconnect plug back into the battery pack
6. Apply new high voltage warning labels to any areas where original labels were damaged during the procedure

Verification

• Using the Rivian diagnostic scan tool, clear any stored fault codes and perform a high voltage system self-test
• Monitor the scan tool while powering on the vehicle - verify no high voltage system faults are present
• Verify the high voltage battery indicator shows normal operation on the instrument cluster
• Perform a visual inspection of all HV connections with the vehicle powered on (do not touch) - look for any arc flash indicators, smoke, unusual smells, or warning lights
• Test vehicle in READY mode - verify both front and rear motors respond properly to throttle input with no warning lights
• Perform a short test drive and verify normal acceleration, regenerative braking, and motor operation with no unusual noises or warning messages
• Test both AC Level 2 charging and DC fast charging if available to verify charging system connections are functional
• After test drive, perform a final visual inspection of all HV connections for any signs of heating, looseness, or damage
• Document completion of work, insulation test results, and all diagnostic scan results in vehicle service records

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