Systematic diagnosis of drivability issues on a 2022 Rivian EDV 500 dual motor AWD electric delivery van, including inspection of high-voltage systems, motor performance, battery health, and drivetrain components.

Warnings

Tools required

Preparation

1. Verify customer complaint in detail, noting specific conditions when drivability issue occurs (acceleration, deceleration, speed range, temperature, etc.)
2. Perform visual inspection of vehicle exterior for accident damage or modifications
3. Check 12V auxiliary battery voltage and condition - low voltage can cause erratic behavior in electric vehicles
4. Ensure vehicle has adequate state of charge (minimum 20%) to perform diagnostic tests safely
5. Place vehicle on level surface and apply parking brake
6. Position wheel chocks at all four wheels
7. Connect diagnostic scan tool and establish communication with all vehicle modules
8. Retrieve and document all current and pending diagnostic trouble codes from all control modules
9. Record freeze frame data and vehicle operating parameters at time of fault
10. Review service history for previous related repairs or software updates

Procedure

1. 1

   Analyze Diagnostic Trouble Codes and Data
   Review all retrieved fault codes with focus on propulsion system, battery management system, drive unit controllers, and traction control modules. Pay particular attention to codes related to motor position sensors, inverter operation, battery cell voltage deviations, and torque reduction events. Cross-reference codes with Rivian technical service bulletins for known issues.
2. 2

   Verify 12V Auxiliary Battery System
   Test 12V auxiliary battery voltage under load. Should read 12.4-12.8V at rest and maintain above 11.5V under 200A load for 15 seconds. Low 12V system voltage causes communication errors between modules and can produce drivability symptoms that mimic high-voltage system faults. Check all 12V system connections and DC-DC converter operation.
3. 3

   Inspect High-Voltage Battery Pack Status
   Using scan tool, review battery pack state of charge, state of health, cell voltage deviation, pack temperature distribution, and insulation resistance. Check for any cell balancing issues or thermal management system faults. Maximum cell voltage deviation should typically be under 30mV during static conditions. Review battery thermal management system operation and coolant temperatures.
4. 4

   Test Drive Unit Operation
   Access live data for both front and rear drive units. Monitor motor temperatures, motor RPM, commanded vs actual torque, inverter temperatures, and resolver/encoder signals during static conditions. Look for unexpected temperature rise, signal noise, or torque delivery discrepancies between commanded and actual values. Verify both motors are available and not in limited power mode.
5. 5

   Perform Controlled Test Drive
   With scan tool data logging active, perform test drive replicating customer complaint conditions. Monitor propulsion system parameters including individual motor torque output, battery current draw, inverter temperatures, motor temperatures, and vehicle speed. Note any torque limiting events, power reduction warnings, or regenerative braking anomalies. Document exact conditions when symptoms occur.
6. 6

   Inspect Motor and Inverter Cooling System
   Check EV transmission fluid level if accessible per service procedures (10 quarts total capacity). Verify cooling system operation for both drive units. Check coolant level in battery/motor cooling system (10 quarts capacity). Inspect cooling system hoses, connections, and radiator for leaks or damage. Use thermal camera if available to identify hot spots indicating cooling system problems.
7. 7

   Evaluate Mechanical Drivetrain Components
   Raise vehicle on lift and secure properly. Inspect front and rear drive units for fluid leaks, mounting integrity, and unusual noise when rotated by hand (high-voltage system de-energized and locked out). Check front differential (1.5 quarts 75W-90 GL-5) and rear differential (2.0 quarts 75W-90 GL-5) for proper fluid level and condition if accessible. Inspect CV axles, half shafts, and universal joints for wear or damage.
8. 8

   Inspect High-Voltage Cabling and Connections
   With proper lockout/tagout procedures followed and wearing insulated gloves, visually inspect all orange high-voltage cables for damage, chafing, or corrosion. Check all high-voltage connector locks and seals. Look for evidence of arcing, discoloration, or heat damage at connections. Verify manual service disconnect is properly installed and making good contact.
9. 9

   Test Traction Control and Stability Systems
   Review ABS/ESC module for faults. Check wheel speed sensor signals and compare all four wheels for consistent data. Erratic wheel speed sensor signals can cause traction control to inappropriately limit motor torque. Verify tire sizes are consistent and match specifications. Check for any suspension damage affecting wheel alignment or sensor operation.
10. 10

    Perform Accelerator Pedal Position Sensor Test
    Monitor accelerator pedal position sensor voltage signals (typically dual redundant sensors). Verify smooth linear progression from idle to wide-open throttle with no dropouts, spikes, or correlation errors between sensors. Compare commanded pedal position to actual motor torque response for delays or non-linear response indicating sensor or calibration issues.
11. 11

    Check Software Calibration Versions
    Using diagnostic tool, verify all control module software versions match current Rivian specifications. Check for available software updates that may address drivability concerns. Document all module part numbers and software calibration versions. Compare against technical service bulletins for required updates related to drivability concerns.
12. 12

    Analyze Motor Resolver/Encoder Signals
    If equipped with oscilloscope capability, analyze motor position sensor signals for noise, dropout, or phase errors. These sensors provide critical feedback for motor control and any degradation causes rough operation, vibration, or power limiting. Check for proper sine/cosine waveform shape and consistent amplitude. Look for electrical interference from high-current motor cables.
13. 13

    Review Thermal Management Strategy
    Analyze battery and drive unit thermal management system operation. Check coolant pump operation, radiator fan control, and coolant valve actuation. Verify system is maintaining proper temperature ranges for battery pack (typically 15-35°C optimal) and drive units (under 70°C continuous operation). Overheating components will trigger power limiting.
14. 14

    Document Findings and Determine Root Cause
    Compile all diagnostic data, fault codes, test drive observations, and inspection findings. Cross-reference symptoms with known failure modes: motor bearing wear causes vibration and noise, inverter failures cause power cuts, battery cell issues cause voltage sag under load, cooling problems cause thermal limiting, sensor faults cause torque delivery problems. Identify specific failed component or system requiring repair.

Reassembly

1. If any components were disconnected for testing, reinstall and torque all fasteners to specification
2. Ensure all high-voltage connectors are properly locked and sealed
3. Verify manual service disconnect is properly installed if it was removed
4. Lower vehicle from lift if raised
5. Clear diagnostic trouble codes only after repairs are completed

Verification

• Reconnect scan tool and verify no new fault codes are present after diagnosis
• Perform test drive under same conditions as original complaint to verify issue is identified
• Review all live data parameters to confirm systems are operating within normal ranges
• Verify state of charge, battery health, and thermal management systems show normal operation
• Document specific failed component or system requiring repair based on diagnostic findings
• Provide customer with detailed explanation of diagnosis and recommended repairs

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