This procedure covers the removal and replacement of a generic relay in the 2025 Rivian EDV 500 electric delivery van's electrical system.

Warnings

Tools required

Parts

• Replacement relay (match existing relay specifications) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off ignition and remove key fob from vehicle interior
3. Allow vehicle to fully power down (approximately 5 minutes after shutdown)
4. Open driver's door to allow access to interior and prevent auto-lock
5. Locate the specific relay requiring replacement using wiring diagram or fault code information
6. Photograph the relay location and orientation before removal for reference

Procedure

1. 1

   Disconnect 12V battery
   Open the front hood and locate the 12V battery in the front compartment. Disconnect the negative terminal first, then the positive terminal. Wait at least 2 minutes for capacitors to discharge before proceeding.
   ⚠Disconnecting the battery will clear temporary fault codes and reset some vehicle settings.
2. 2

   Access relay location
   Depending on relay location, remove necessary access panels. For front power distribution module, remove the plastic cover by unclipping the retaining tabs. For underdash relays, remove the lower dash panel below the steering column using trim removal tools. For rear module, access from cargo area and remove appropriate cover panels.
3. 3

   Identify the target relay
   Locate the specific relay using the diagram printed on the fuse/relay box cover or refer to the service manual. Cross-reference the relay position with the fault code or symptom being addressed. Note the relay amperage rating and part number printed on the relay body.
4. 4

   Document relay configuration
   Before removal, take a clear photograph showing the relay position and orientation in the relay box. Note which direction the relay tabs are facing and any identifying markings on the relay and socket.
5. 5

   Test relay socket terminals
   Using a digital multimeter, inspect the relay socket for proper terminal condition. Check for corrosion, pushed-back pins, or damage. If socket is damaged, the entire fuse/relay box may require replacement.
6. 6

   Remove the faulty relay
   Firmly grasp the relay body and pull straight upward with steady pressure. If the relay is difficult to remove, use needle-nose pliers or a relay removal tool to grip the relay body and pull vertically. Do not rock side-to-side as this can bend socket terminals.
   ⚠Excessive force or angled removal can damage socket terminals permanently.
7. 7

   Inspect removed relay
   Examine the removed relay for signs of failure including burned or melted plastic, corrosion on terminals, or rattling sound when shaken (indicating broken internal components). Check terminal blades for discoloration or pitting.
8. 8

   Test removed relay (optional)
   Using a multimeter and external 12V power source, test the removed relay function. Apply voltage to the coil terminals (typically 85 and 86) and check for continuity between the switch terminals (typically 30 and 87) to confirm relay failure.
9. 9

   Verify replacement relay specifications
   Confirm the new relay matches the original exactly in terms of amperage rating, terminal configuration, and physical dimensions. Verify the relay part number matches Rivian specifications or approved equivalent. Do not substitute with incorrect relay type.
   ⚠️Installing a relay with incorrect amperage rating can cause circuit damage or electrical fire.
10. 10

    Apply dielectric grease (optional)
    Apply a thin coat of dielectric grease to the new relay terminals to prevent corrosion and ensure good electrical contact. Do not over-apply as excess grease can attract dirt.
11. 11

    Install new relay
    Align the new relay with the socket, ensuring proper orientation based on documentation from step 4. Press the relay firmly and evenly into the socket until it seats completely. The relay should be flush with surrounding relays and should not rock or sit at an angle.
12. 12

    Reconnect 12V battery
    Reconnect the positive terminal first, then the negative terminal to the 12V battery. Ensure connections are clean and tight.
13. 13

    Perform system verification
    Turn the ignition to ON position without starting. Monitor dashboard for warning lights related to the replaced relay circuit. Cycle the affected system (lights, HVAC, etc.) multiple times to verify proper relay operation.
14. 14

    Scan for fault codes
    Connect diagnostic tool and scan all modules for active or pending fault codes. Clear codes if appropriate and verify no new codes are present. Test drive vehicle if relay is related to drive systems.
15. 15

    Reinstall access panels
    Replace all removed covers, panels, and trim pieces. Ensure all clips are fully engaged and panels are secure. Verify fuse/relay box cover is properly seated and latched.

Reassembly

1. Ensure all electrical connections are secure and properly seated
2. Verify all access panels and covers are reinstalled correctly
3. Confirm no tools or parts are left in fuse/relay boxes or behind panels
4. Test all affected electrical systems for proper function

Verification

• Verify the affected electrical circuit operates correctly with multiple on/off cycles
• Confirm no warning lights are illuminated on the instrument cluster
• Scan for fault codes with diagnostic tool - no relay-related codes should be present
• Listen for proper relay clicking sound during system activation if audible
• Verify relay remains properly seated and does not vibrate loose during test drive
• Confirm all vehicle systems that were affected by battery disconnection have been reset or relearned

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