This procedure covers the removal, replacement, and programming of the Battery Management System (BMS) module on a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Battery Management System module × 1 — Use OEM specification
• High-voltage interlock connector seal × 1 — Use OEM specification
• BMS mounting hardware kit × 1 — Use OEM specification
• Battery coolant (if drained) × 1 — EV Battery/Motor Coolant

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is powered off completely and key fob is at least 20 feet away
3. Place high-voltage warning signs around vehicle work area
4. Review vehicle-specific service bulletins for BMS-related updates
5. Verify replacement BMS module part number matches vehicle configuration
6. Ensure Rivian diagnostic software is updated to latest version
7. Document any active fault codes before beginning work
8. Photograph all connector orientations and cable routing before disassembly

Procedure

1. 1

   Disable high-voltage system
   Open the front hood and locate the high-voltage disconnect (HVD) service panel on the driver side of the battery pack. Using insulated tools, remove the service panel cover. Pull the high-voltage service disconnect handle straight up and remove it completely from the vehicle. Place disconnect in a secure location away from vehicle. Verify the HV disconnect indicator light is off.
2. 2

   Wait for capacitor discharge
   Wait a minimum of 10 minutes to allow all high-voltage capacitors to fully discharge. Set a timer to ensure full discharge time is observed. During this time, prepare tools and workspace.
3. 3

   Verify zero voltage
   Don high-voltage safety gloves. Using a high-voltage capable digital multimeter, verify zero voltage between HV positive and negative bus bars at the service disconnect location. Voltage reading must be below 5V DC. Also check voltage between each HV bus bar and vehicle chassis ground. Document all readings.
4. 4

   Disconnect 12V battery
   Locate the 12V auxiliary battery in the front compartment. Disconnect the negative terminal first, then positive terminal. Secure cables away from terminals. Wait 2 minutes for all vehicle modules to power down completely.
5. 5

   Remove cargo area floor panels
   Open rear cargo doors. Remove all cargo area floor covering and panels to access the battery pack top cover. The BMS module is located on the top surface of the battery pack, centered toward the rear section. Remove fasteners securing floor panels and store safely.
6. 6

   Remove battery pack top cover
   Locate and remove all fasteners securing the battery pack top cover section above the BMS location. There are multiple bolts around the perimeter. Carefully lift the cover panel straight up to avoid damaging seals or harness routing clips. Set cover aside on clean protected surface.
7. 7

   Disconnect BMS electrical connections
   Locate the BMS module mounted on top of the battery pack. Identify all electrical connectors: main communications connector, cell voltage sense ribbon cables (multiple), temperature sensor harnesses, and cooling system connections. Release each connector lock and carefully disconnect all connectors from BMS. Use plastic trim tools to release locking tabs without damaging connectors. Label each connection for reassembly.
8. 8

   Disconnect cooling lines if equipped
   If BMS has active cooling connections, carefully disconnect coolant supply and return lines from the BMS module. Have drain pan ready to catch residual coolant (approximately 1-2 quarts). Cap open lines immediately to prevent contamination and moisture ingress. Note routing of coolant lines for reinstallation.
9. 9

   Remove BMS mounting fasteners
   Remove all mounting bolts securing the BMS module to the battery pack. Store bolts in organized manner noting original locations as some may be different lengths. Check for any additional grounding straps or brackets that must be removed.
10. 10

    Remove BMS module
    Carefully lift BMS module straight up from mounting location. The module may have thermal interface material on the bottom surface creating slight adhesion. Do not pry or force. Once free, remove module from vehicle and place on clean ESD-safe work surface. Inspect mounting surface on battery pack for damage or debris.
11. 11

    Prepare battery pack mounting surface
    Clean the BMS mounting surface on battery pack using isopropyl alcohol and lint-free cloth. Remove any old thermal interface material completely. Inspect cell voltage sense contact pads for corrosion or damage. Surface must be completely clean and dry before new module installation.
12. 12

    Install new BMS module
    Apply new thermal interface material to battery pack mounting surface per Rivian specifications if required. Carefully align new BMS module with mounting holes and cell sense contact points. Lower module straight down ensuring all alignment pins engage properly. Do not slide module once contact is made with thermal interface material.
13. 13

    Install mounting hardware
    Install all BMS mounting bolts hand-tight first to ensure proper alignment. Tighten bolts in star pattern to ensure even contact pressure. Use torque values per service manual specifications. Install any grounding straps removed earlier.
14. 14

    Reconnect all electrical connections
    Reconnect all electrical connectors to new BMS module in reverse order of removal. Ensure each connector is fully seated and locking tabs engage with audible click. Pay special attention to cell voltage sense ribbon cables ensuring proper alignment and no pin damage. Verify high-voltage interlock circuit connector seal is new and properly installed.
15. 15

    Reconnect cooling lines if equipped
    If applicable, reconnect coolant supply and return lines to BMS module. Ensure connections are fully seated and secure. If significant coolant was lost, system will need refilling and bleeding per separate coolant service procedure.

Reassembly

1. Reinstall battery pack top cover ensuring all seals are properly positioned and fasteners torqued to specification
2. Route all wiring harnesses in original locations using new cable ties as needed
3. Reinstall cargo area floor panels and covering
4. Reconnect 12V battery positive terminal first, then negative terminal
5. Before reinstalling HV disconnect, connect diagnostic software to vehicle
6. Perform BMS programming and configuration using Rivian diagnostic software following all on-screen prompts
7. Enter vehicle VIN and battery pack serial number when prompted
8. Allow BMS to complete cell balancing initialization (may take 30-60 minutes)
9. Clear all fault codes and verify no new codes present

Verification

• With diagnostic software connected, verify BMS module communication is established
• Confirm all battery cell voltages are reading correctly and within acceptable range (typically 3.6-4.1V per cell)
• Verify all temperature sensors are reporting valid readings
• Check that State of Charge (SOC) calculation is functioning
• Reinstall high-voltage service disconnect and verify HV system activates properly
• Perform high-voltage isolation test using diagnostic software - must show >500 ohms isolation resistance
• Power vehicle to READY mode and verify no warning lights or fault codes
• Test drive vehicle briefly and monitor BMS operation through diagnostic software
• Verify regenerative braking functions correctly
• Perform final diagnostic scan and document all system parameters are within normal range
• If coolant system was serviced, verify no leaks and proper coolant level after system reaches operating temperature

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