Comprehensive diagnostic test of the high-voltage battery pack to evaluate state of charge, capacity, cell balance, and overall battery health using Rivian diagnostic equipment.

Warnings

Tools required

Parts

• High-voltage connector seals (if damaged during inspection) × 1 — Use OEM specification

Preparation

1. Verify vehicle has been at rest for minimum 2 hours and battery temperature is between 68-77°F (20-25°C)
2. Place vehicle on level surface and apply parking brake firmly
3. Place wheel chocks at all four wheels
4. Ensure vehicle state of charge is between 40-80% for optimal testing results
5. Clear all diagnostic trouble codes and note any existing HV battery fault codes
6. Document current odometer reading and battery health percentage from driver display
7. Set up safety perimeter around vehicle with warning signs indicating high-voltage work in progress
8. Put on high-voltage insulated gloves and verify they are free from damage or punctures
9. Ensure fire extinguisher rated for electrical fires (Class C) is readily accessible

Procedure

1. 1

   Disable High-Voltage System
   Access the vehicle settings through the center display. Navigate to Service Mode and select 'Disable HV System'. Enter the service PIN if required. Confirm that the HV system status shows 'Disabled' on the instrument cluster. Wait minimum 5 minutes for high-voltage capacitors to discharge completely.
2. 2

   Perform Visual Battery Pack Inspection
   Raise vehicle on lift or use jack stands to access underside. Inspect battery pack enclosure for physical damage, dents, or punctures. Check for signs of coolant leakage around battery pack perimeter and coolant connections. Inspect all orange high-voltage cables for damage, chafing, or exposure. Look for corrosion on connectors and terminals. Document any abnormalities with photos.
3. 3

   Connect Diagnostic Equipment
   Connect Rivian Factory Diagnostic Tool to the OBD-II port located under the driver side dashboard. Power on the diagnostic tool and establish communication with the Battery Management System (BMS). Verify software version is current and compatible with 2022 EDV 500 model. Select 'Battery Test' from the diagnostic menu.
4. 4

   Retrieve Battery System Information
   Use diagnostic tool to retrieve and record: total battery pack voltage, current state of charge (SOC), state of health (SOH), battery pack temperature, individual module temperatures, total cycles count, and maximum/minimum cell voltages. Compare values to Rivian factory specifications for EDV 500. Note any parameters outside normal range.
5. 5

   Perform Cell Balance Analysis
   Access the cell voltage monitoring function in diagnostic tool. Review voltage of all individual cells or cell groups (typically 108 cell groups in Rivian pack). Record the highest and lowest cell voltages. Calculate voltage delta (difference between highest and lowest). Acceptable delta is less than 50mV. If delta exceeds 100mV, battery pack requires balancing or may have failing cells.
6. 6

   Execute Isolation Resistance Test
   Within diagnostic tool, initiate the high-voltage isolation test. This test measures resistance between the HV+ and HV- terminals and vehicle chassis ground. Minimum acceptable resistance is 500 ohms per volt of pack voltage (typically 400kΩ minimum for EDV 500). Values below this indicate potential insulation breakdown and require immediate attention. Record actual measured resistance values.
7. 7

   Check Battery Cooling System
   Verify battery coolant level in reservoir is within acceptable range using diagnostic tool or visual inspection of coolant reservoir under hood. Check coolant pump operation by commanding pump activation through diagnostic tool. Listen for pump operation and monitor coolant temperature sensors for response. Verify coolant temperature difference between inlet and outlet is within 5°F during pump operation.
8. 8

   Perform Static Capacity Test
   Initiate the battery capacity estimation routine in diagnostic tool. This uses BMS data and algorithms to calculate available capacity without full discharge/charge cycle. System will calculate usable kWh and compare to original design capacity (approximately 120 kWh usable for EDV 500). Record results. Capacity below 85% of original may indicate degradation requiring customer notification.
9. 9

   Inspect High-Voltage Contactors
   Use diagnostic tool to command HV contactors open and closed while monitoring status. Listen for audible click of contactor operation. Check contactor resistance values reported by BMS - should be less than 1 milliohm when closed, infinite when open. Verify no welding or pitting of contactor surfaces by reviewing contactor cycle count and any stored contactor fault codes.
10. 10

    Review Battery Management System Logs
    Access BMS event logs through diagnostic tool. Review history for any over-voltage, under-voltage, over-temperature, or over-current events. Check for cell balancing events and frequency. Note any emergency disconnect events or crash signals. Document any abnormal patterns or recurring faults that may indicate intermittent issues.
11. 11

    Thermal Imaging Scan (If Equipment Available)
    If thermal camera is available, re-enable HV system and allow vehicle to idle for 5 minutes. Perform thermal scan of battery pack underside looking for hot spots or uneven temperature distribution. Temperature variation across pack should be less than 10°F. Hot spots may indicate failing cells or cooling system restrictions. Document thermal images for records.
12. 12

    Generate Diagnostic Report
    Use diagnostic tool to compile comprehensive battery health report including all test results, cell voltages, temperatures, capacity calculations, and any fault codes. Save report to diagnostic tool and export for customer records. Compare all values against Rivian factory specifications. Determine if battery passes, requires monitoring, or needs service based on test results.

Reassembly

1. If any high-voltage connectors were disconnected during inspection, reconnect and ensure positive engagement with audible click
2. Apply new connector seals if originals were damaged during inspection
3. Lower vehicle from lift or jack stands safely
4. Remove wheel chocks
5. Re-enable high-voltage system through vehicle service menu
6. Clear service mode and restore vehicle to normal operation
7. Verify no new diagnostic trouble codes are present after re-enabling HV system

Verification

• Confirm vehicle starts normally and ready-to-drive indicator illuminates properly
• Verify battery state of charge displays correctly on instrument cluster
• Check that no HV system warning lights are illuminated
• Confirm battery cooling fan operates when commanded through climate control
• Test drive vehicle briefly to verify normal operation and power delivery
• Verify all test data has been saved to vehicle service records and diagnostic tool
• Review test results with customer and provide written summary of battery health status

More procedures for this vehicle