Complete diagnostic test of the high-voltage charging system including onboard charger, DC fast charging capability, charge port functionality, and battery management system charging parameters for the Rivian EDV 500 electric delivery van.

Warnings

Tools required

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure battery state of charge is between 20-80% for optimal testing conditions
3. Verify vehicle has been stationary for at least 30 minutes to allow systems to stabilize
4. Connect Rivian diagnostic tool to OBD-II port and establish communication with vehicle control modules
5. Document any existing fault codes related to charging system before beginning tests
6. Ensure ambient temperature is within acceptable range for charging system operation
7. Verify charge port door opens and closes properly via exterior button and interior controls

Procedure

1. 1

   Initial System Scan and Baseline Data Collection
   Using the diagnostic tool, perform a complete vehicle scan focusing on Battery Management System (BMS), Onboard Charger Module, Charge Port Control Module, and High Voltage Battery Controller. Record all present and pending fault codes. Capture baseline data including battery pack voltage, individual cell voltages, battery temperature sensors (minimum 8 sensor readings), state of charge, state of health, and charging system status flags. Verify communication with all charging-related modules is established.
2. 2

   Charge Port Physical Inspection and Functional Test
   Inspect charge port receptacle for physical damage, corrosion, foreign debris, or signs of overheating on pins. Check for bent or damaged contact pins. Verify charge port locking mechanism operates correctly. Test charge port illumination. Using diagnostic tool, command charge port door open and closed to verify actuator function. Check weather sealing and drainage channels are clear. Inspect charge port wiring harness for damage, chafing, or signs of water intrusion at connector points.
3. 3

   High-Voltage System Isolation Verification
   With vehicle in Park and powered off, use diagnostic tool to verify high-voltage contactors are open. Using insulation resistance tester, measure isolation resistance between HV+ and vehicle chassis ground, then HV- and vehicle chassis ground. Resistance should exceed 500 ohms per volt of pack voltage (minimum 200 megohms for 400V pack). Record readings. Low isolation resistance indicates potential HV system leakage requiring immediate investigation before proceeding with charging tests.
   ⚠️Ensure high-voltage system is confirmed de-energized before performing isolation resistance testing. Verify all HV contactors are open via diagnostic tool.
4. 4

   Onboard Charger Pre-Test Inspection
   Locate onboard charger module assembly (typically mounted in front cargo area near high-voltage battery). Visually inspect for physical damage, coolant leaks, or signs of thermal stress. Check all electrical connections to onboard charger are secure and show no signs of overheating. Verify cooling system passages to charger are not blocked. Using diagnostic tool, check onboard charger internal temperature sensors and verify readings are consistent with ambient temperature before charging test begins.
5. 5

   Level 2 AC Charging System Test
   Connect portable Level 2 EVSE (minimum 32 amp, 240V capability) to vehicle charge port. Using diagnostic tool, monitor charging initiation sequence: pilot signal detection, charge port lock engagement, HV contactor closure, and charging current ramp-up. Verify vehicle successfully negotiates maximum charge rate with EVSE. Allow vehicle to charge for minimum 15 minutes while monitoring: AC input voltage and current, DC output voltage and current from onboard charger, battery pack temperature rise rate, onboard charger temperature, and charging efficiency calculations. Record peak charging power acceptance.
6. 6

   AC Charging System Parameter Verification
   During active Level 2 charging, verify the following parameters are within specification using diagnostic tool: AC input voltage 208-240V, AC input current matches negotiated rate (typically 32A maximum for EDV 500), DC charging current to battery pack, individual battery cell voltage balance (all cells within 0.030V during charging), battery pack temperature uniformity (maximum 5°C difference between sensors), onboard charger coolant temperature if equipped, and power factor correction operation. Check for any intermittent fault codes during charging session.
7. 7

   Charge Port Communication Protocol Test
   Stop charging and disconnect EVSE. Using diagnostic tool, access charge port control module and verify proper pilot signal detection and voltage levels. Reconnect EVSE and monitor J1772 pilot signal communication (1kHz PWM signal with duty cycle indicating available current). Verify vehicle correctly interprets EVSE current capacity from pilot signal duty cycle. Test charge port proximity detection circuit confirms plug insertion. Verify charge port locking mechanism engages when charging is active and releases when charging stops or emergency release is activated.
8. 8

   DC Fast Charging Capability Test (If Equipped/Available)
   If DC fast charging capability test is required and CCS charging station is available, connect vehicle to DC fast charger. Monitor CCS communication handshake between vehicle and charger using diagnostic tool. Verify vehicle requests appropriate charging parameters based on battery state of charge and temperature. Observe DC charging power curve - should reach peak power (typically 100-150kW for EDV 500) when battery is between 10-50% SOC. Monitor battery thermal management system activation. Record charging power at various SOC levels. Test should run minimum 10 minutes or until charging power begins to taper.
9. 9

   Battery Thermal Management During Charging
   During either AC or DC charging test, monitor battery thermal management system operation. Verify battery coolant pump activates when needed. Check coolant temperature differential across battery pack (inlet vs outlet). Monitor individual battery module or section temperatures to ensure even thermal distribution. Verify battery heating system operates if charging at low ambient temperature (below 10°C). Check that charging power is modulated appropriately if battery temperature approaches upper limit (typically 40-45°C). Inspect for proper coolant flow using diagnostic data parameters.
10. 10

    Charging System Safety Interlock Verification
    Perform safety interlock tests with vehicle connected to EVSE but not actively charging. Verify charging cannot initiate when vehicle is not in Park. Test that opening driver or cargo doors does not interrupt established charging session. Verify charge port manual emergency release terminates charging immediately. Test that shifting out of Park while connected but not charging does not damage system. Confirm 12V battery low-voltage condition prevents charging initiation. Verify proper warning messages display on driver cluster during interlock conditions.
11. 11

    Scheduled Charging and Charge Management Functions
    Using vehicle interface and diagnostic tool, test scheduled charging functionality. Program a delayed charge start time and verify vehicle waits to begin charging when connected to EVSE. Test charge limit setting (e.g., charge to 80%) and verify charging stops at programmed limit. Check preconditioning function if equipped (battery/cabin conditioning while connected to shore power). Verify charge status can be monitored remotely via vehicle telematics if equipped. Test that utility rate-based charging schedules function correctly if programmed.
12. 12

    Post-Charging System Evaluation
    After completing all charging tests, allow vehicle to sit for 5 minutes with no charging activity. Perform final diagnostic scan and compare fault codes to baseline recorded in Step 1. Verify all new or pending codes are documented. Check for any logged charging interruption events or thermal protection activations. Review charging session data logs if available. Measure battery pack voltage and verify it matches expected voltage for current state of charge. Check that battery cell balance remains within specification (maximum 0.030V deviation across pack).
13. 13

    Thermal Imaging Inspection (If Available)
    If thermal imaging camera is available, perform thermal scan of charging system components after completing charging test while components are still warm. Inspect onboard charger module for hot spots indicating component stress or failure. Check charge port pins for even temperature distribution (uneven heating indicates poor contact or corrosion). Scan high-voltage cabling for any thermal anomalies. Inspect battery pack enclosure for temperature uniformity. Document any temperature readings exceeding normal operating range or showing significant variation from adjacent components.
14. 14

    Final System Verification and Documentation
    Generate comprehensive diagnostic report including all fault codes, charging system data parameters, charging power curves, battery thermal data, and any anomalies observed during testing. Clear any temporary or test-related fault codes that occurred during diagnostic procedures. Verify all permanent fault codes are documented for further diagnosis if needed. Confirm vehicle returns to normal ready-to-drive state. Test that vehicle propulsion system operates normally after charging system testing. Document charging system health status and any recommendations for follow-up service or component replacement.

Reassembly

1. Ensure charge port door closes and latches properly
2. Verify all diagnostic tool connections are removed
3. Confirm all access panels or covers removed during inspection are reinstalled
4. Clear diagnostic tool from vehicle systems and verify no active communication is preventing vehicle sleep mode

Verification

• Verify all charging system fault codes are either resolved or properly documented
• Confirm vehicle accepts charge from both Level 2 AC source and DC fast charging (if applicable) without interruption
• Verify battery pack voltage and state of charge display correctly on instrument cluster
• Check that charging power levels meet manufacturer specifications for vehicle age and battery condition
• Confirm all safety interlocks function properly and prevent unsafe charging conditions
• Verify battery thermal management operates correctly during charging
• Ensure charge port communication with EVSE equipment is reliable and immediate
• Test drive vehicle briefly to confirm propulsion system operates normally after charging system testing
• Verify remote charging status monitoring functions correctly if equipped with telematics

More procedures for this vehicle