Battery Disconnect Service

This procedure safely disconnects the high-voltage battery system on a 2022 Rivian EDV 500, isolating all electrical power for service work requiring complete system de-energization.

Warnings

Tools required

Parts

• High-voltage connector protective caps × 2 — Use OEM specification
• Service plug seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks at all four wheels
3. Verify vehicle is NOT connected to any charging equipment
4. Ensure battery coolant system has cooled to ambient temperature (minimum 2 hours after last drive)
5. Verify all occupants have exited vehicle and all doors are closed
6. Have Class C fire extinguisher readily accessible
7. Review Rivian high-voltage safety training materials and emergency response procedures
8. Prepare lockout/tagout documentation and tags

Procedure

1. 1

   Disable vehicle systems and disconnect 12V battery
   Press brake pedal and press power button to ensure vehicle is in OFF mode. Verify all interior lights and displays are off. Open frunk and locate 12V auxiliary battery on driver side. Disconnect negative terminal first using 10mm socket, then disconnect positive terminal. Secure cables away from battery posts. Wait 2 minutes for all vehicle control modules to power down completely.
2. 2

   Access underbody high-voltage service area
   Raise vehicle using floor jack at designated lift points. Support on jack stands rated for vehicle weight (minimum 7000 lbs capacity). Remove plastic underbody panels beneath center of vehicle using T30 Torx bit to access high-voltage battery pack service area. Locate the high-voltage service disconnect cover marked with orange warning labels on driver side of battery pack.
3. 3

   Remove high-voltage service disconnect cover
   Put on high-voltage insulated gloves. Remove service disconnect cover by releasing four T40 Torx fasteners. Carefully set cover aside. Visually inspect service disconnect area for any damage, corrosion, or coolant leakage. If any damage is present, stop procedure and consult Rivian technical support.
4. 4

   Verify high-voltage presence
   Using high-voltage capable multimeter, carefully measure voltage at high-voltage service disconnect terminals through inspection ports without making direct contact with gloves. Voltage should read between 350-450V DC depending on battery state of charge. Document voltage reading for later verification. This confirms system is energized before disconnect.
5. 5

   Remove high-voltage service disconnect plug
   Grasp the orange service disconnect handle firmly. Rotate the locking mechanism counterclockwise 90 degrees until it stops. Pull straight out with steady force to extract service plug from battery pack housing. The plug should extract approximately 6 inches. Do NOT twist or rock the plug during removal. Place removed service plug in a secure, dry location away from work area.
6. 6

   Install lockout device and wait for capacitor discharge
   Install lockout/tagout device into service plug cavity to prevent reinsertion. Attach service tag with technician name, date, and reason for disconnect. Set timer for minimum 10 minutes to allow high-voltage system capacitors to discharge. Do NOT proceed to next step until full 10 minutes have elapsed. Keep all personnel away from vehicle during discharge period.
7. 7

   Verify zero voltage state
   After 10-minute waiting period, use high-voltage multimeter to verify voltage at service disconnect terminals reads less than 5V DC. Test multiple times over 2-minute period to confirm voltage remains at zero. If voltage is above 5V, wait additional 5 minutes and retest. Document zero-voltage verification in service records.
8. 8

   Disconnect high-voltage battery coolant connections (if required)
   If service requires coolant system access, locate coolant quick-disconnect fittings on battery pack. Place drain pan beneath connections. Press release tabs on quick-disconnects and separate coolant lines. Expect approximately 4-6 oz of coolant spillage. Install protective caps on both coolant line ends and battery pack ports. Mark lines for proper reconnection.
9. 9

   Disconnect auxiliary high-voltage connections
   Locate orange high-voltage cables running from battery pack to motor drive units. Release secondary locking clips on HV connectors by pressing release tabs. Grasp connector bodies (not cables) and pull straight apart with firm, even pressure. Install protective orange caps on all exposed high-voltage terminals immediately after separation. Secure disconnected cables with zip ties to prevent contact with vehicle components.
10. 10

    Document battery disconnect status
    Apply visible lockout/tagout tags at service disconnect location, frunk 12V battery area, and driver door window. Take photographs of all disconnect points showing lockout devices in place. Record in service documentation: date, time, technician name, reason for disconnect, voltage readings before and after disconnect, and expected duration of disconnect state. Place warning placard on driver seat indicating high-voltage system is disabled.

Reassembly

1. Verify all high-voltage components are clean and free of debris before reconnection
2. Remove protective caps from high-voltage connectors only immediately before reconnection
3. Ensure high-voltage cable connectors are fully seated with audible click and secondary locks engaged
4. Reconnect battery coolant lines if disconnected, ensuring quick-disconnects are fully latched
5. Inspect service plug contacts for damage or corrosion before reinsertion
6. Insert service plug straight into housing until fully seated, rotate locking mechanism clockwise 90 degrees
7. Remove lockout/tagout devices and warning tags
8. Reinstall service disconnect cover with all four T40 Torx fasteners
9. Reinstall underbody panels and lower vehicle from jack stands
10. Reconnect 12V battery: positive terminal first, then negative terminal

Verification

• With vehicle still unpowered, perform visual inspection of all high-voltage connection points for proper seating and locking
• Verify service disconnect cover is properly secured and sealed
• Power on vehicle and check for any high-voltage system fault codes using diagnostic tool
• Verify battery coolant system shows no leaks and proper pressure (if coolant was disconnected)
• Confirm all vehicle systems initialize normally: propulsion ready indicator, HVAC, displays
• Test drive vehicle at low speed in safe area to verify normal drivetrain operation
• Monitor battery thermal management system operation for 10 minutes after power-on
• Clear any nuisance fault codes that may have set during extended disconnect period
• Document successful reconnection with all verification checks passed in service records

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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