This procedure covers the removal and replacement of the DC-DC converter on a 2022 Rivian EDV 500, which converts high-voltage battery power to 12V for vehicle accessories.

Warnings

Tools required

Parts

• DC-DC converter assembly × 1 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification
• Thermal interface pad × 1 — Use OEM specification
• 12V connector seal × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 1 qt

Preparation

1. Ensure the vehicle has been off for at least 2 hours to allow high-voltage components to cool
2. Place the vehicle on a level surface and engage the parking brake
3. Raise and support the vehicle on jack stands or a service lift
4. Remove the front underbody splash shield to access the high-voltage components
5. Connect the Rivian diagnostic scan tool and document any existing fault codes
6. Put on high-voltage insulated gloves and safety equipment
7. Disconnect the 12V auxiliary battery negative terminal
8. Take detailed photos of the DC-DC converter area, all cable routing, and connector orientations for reassembly reference

Procedure

1. 1

   Disable high-voltage system
   Using the Rivian service software, initiate the high-voltage system lockout procedure. This will open all high-voltage contactors and place the vehicle in service mode. Verify the system is in lockout mode on the diagnostic tool display. Apply the high-voltage lockout tag to the steering wheel as per Rivian service procedures.
2. 2

   Wait for capacitor discharge
   Wait a minimum of 10 minutes after initiating high-voltage lockout to allow all high-voltage capacitors to fully discharge. Do not proceed until the full 10 minutes has elapsed. Set a timer to ensure compliance.
3. 3

   Verify zero voltage
   Using a calibrated high-voltage multimeter, verify zero voltage at the high-voltage service disconnect point and at the DC-DC converter input terminals. Voltage must read below 5V DC before proceeding. Document the voltage readings.
4. 4

   Drain partial coolant
   Locate the coolant drain point near the DC-DC converter assembly. Place a drain pan underneath. Open the drain valve and drain approximately 1 quart of coolant, or until coolant stops flowing from the DC-DC converter coolant lines. Close the drain valve when complete.
5. 5

   Disconnect coolant lines
   Locate the two coolant quick-disconnect fittings on the DC-DC converter. Press the release tabs on each quick-disconnect fitting and pull the coolant lines straight away from the converter. Have shop towels ready to catch residual coolant. Cap the open coolant lines with dust caps to prevent contamination.
6. 6

   Disconnect 12V output cable
   Locate the large 12V output cable connected to the bottom of the DC-DC converter. Remove the protective cover. Use the appropriate socket to remove the 12V cable terminal bolt. Carefully lift the terminal away from the converter post. Inspect the terminal for corrosion and clean if necessary.
7. 7

   Disconnect high-voltage input connector
   Locate the orange high-voltage input connector on the DC-DC converter. Release the locking tab by pressing the release mechanism while gently pulling the connector away from the converter. Do not pull on the cable itself. The connector should slide straight off. Inspect the connector seal and replace if damaged.
8. 8

   Disconnect communication harness
   Locate the low-voltage communication connector on the side of the DC-DC converter. Press the locking tab and disconnect the connector. Secure the loose connector away from the work area to prevent damage.
9. 9

   Remove mounting hardware
   Locate the DC-DC converter mounting bolts (typically 4 bolts securing the unit to the mounting bracket). Support the weight of the converter with one hand or have an assistant support it. Remove all mounting bolts and retain them for reinstallation. Note the location of any ground straps or brackets.
10. 10

    Remove DC-DC converter
    Carefully lift the DC-DC converter assembly up and out of its mounting location. The unit weighs approximately 20-25 lbs. Be mindful of any remaining cable connections or brackets. Place the old converter on a clean work surface for comparison with the new unit.
11. 11

    Inspect mounting location
    Inspect the mounting bracket for damage, corrosion, or debris. Clean the mounting surface thoroughly. Check that the thermal interface surface on the mounting bracket is clean and free of old thermal pad material. Remove any remnants of the old thermal pad using a plastic scraper.
12. 12

    Prepare new DC-DC converter
    Unpack the new DC-DC converter and compare it to the old unit to ensure correct part. Install the new thermal interface pad onto the base of the new converter, ensuring proper alignment with the mounting surface. Remove protective caps from the coolant ports and electrical terminals.
13. 13

    Install new DC-DC converter
    Carefully position the new DC-DC converter into the mounting location, ensuring the thermal pad makes full contact with the mounting bracket. Align the mounting bolt holes. Install all mounting bolts hand-tight first, then torque in a cross-pattern to ensure even pressure on the thermal interface. Use proper torque specifications per Rivian service manual.
14. 14

    Reconnect all connections
    Reconnect the low-voltage communication connector first, ensuring it clicks into place. Connect the high-voltage input connector, aligning the keying features and pushing firmly until the locking tab engages. Install the 12V output cable terminal onto the converter post and torque the terminal bolt per specifications. Reconnect both coolant quick-disconnect fittings, pushing firmly until they click into place.
15. 15

    Refill and bleed cooling system
    Using EV Battery/Motor Coolant, refill the cooling system to the proper level through the expansion tank. Follow Rivian cooling system bleeding procedure using the service software to activate coolant pumps and purge air from the system. Check for coolant leaks at the DC-DC converter connections. Top off coolant as needed after bleeding.

Reassembly

1. Verify all electrical connections are fully seated and locked
2. Verify coolant quick-disconnects are fully engaged with no leaks
3. Reinstall the front underbody splash shield
4. Reconnect the 12V auxiliary battery negative terminal
5. Remove the high-voltage lockout tag from the steering wheel
6. Lower the vehicle from the lift or jack stands

Verification

• Using Rivian service software, exit high-voltage lockout mode and reactivate the high-voltage system
• Monitor the diagnostic scan tool for any new fault codes related to the DC-DC converter
• Verify the 12V system voltage is between 13.5-14.5V with the vehicle in ready mode
• Check for proper operation of all 12V accessories (lights, HVAC, infotainment, etc.)
• Verify no coolant leaks are present at the DC-DC converter connections
• Use the scan tool to monitor DC-DC converter temperature and output parameters during a 10-minute test run
• Perform a final visual inspection of all connections and verify proper cable routing matches pre-disassembly photos
• Clear any stored fault codes if the DC-DC converter is operating normally
• Test drive the vehicle and verify all systems function properly under load

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