Comprehensive electrical system diagnosis procedure for the 2022 Rivian EDV 500, including high-voltage and low-voltage system testing, module communication verification, and fault code analysis.

Warnings

Tools required

Parts

• Replacement fuses (assorted) × 1 — Use OEM specification
• Electrical contact cleaner × 1 — Dielectric safe cleaner
• Dielectric grease × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered down completely and key fob is at least 15 feet away
3. Verify 12V battery is fully charged (12.4V or higher at rest) as low voltage can cause false diagnostic codes
4. Document all customer complaints in detail, including when issue occurs and environmental conditions
5. Perform visual inspection of vehicle for obvious damage, aftermarket installations, or modifications
6. Check for any open recalls or technical service bulletins related to electrical issues
7. Ensure diagnostic equipment is updated with latest Rivian software version
8. Put on appropriate personal protective equipment including insulated gloves if HV system access is needed

Procedure

1. 1

   Perform Initial System Scan
   Connect diagnostic scan tool to OBD-II port located under driver side dashboard. Power on vehicle to accessory mode without entering ready mode. Perform complete vehicle scan to retrieve all diagnostic trouble codes (DTCs) from all modules including powertrain, body, chassis, infotainment, and high-voltage battery management system. Document all codes, freeze frame data, and failure counters. Note which codes are current versus history.
2. 2

   Verify 12V Battery and Charging System
   Test 12V lithium-ion auxiliary battery state of charge and health. Measure resting voltage (should be 12.4-13.2V). Check DC-DC converter output while vehicle is in ready mode (should maintain 13.5-14.5V). Verify 12V battery connections are clean and tight at both positive terminal in front trunk area and ground points. Check for parasitic draw with vehicle asleep (should be less than 50mA after all modules sleep, typically 15-20 minutes).
3. 3

   Inspect High-Voltage System Status
   Using scan tool, review HV battery status including state of charge, individual cell voltages, pack temperature, isolation resistance, and contactors status. Verify all cell voltages are within 0.05V of each other. Check for any HV system isolation faults which indicate potential current leakage to chassis ground. Review HV battery cooling system operation and verify coolant pump activation. Do not physically access HV components unless proper de-energization procedures are followed.
4. 4

   Test Communication Networks
   Verify communication on all vehicle networks. Check CAN High-Speed (500 kbps), CAN Flexible Data-rate, and Ethernet backbone. Use scan tool to identify any modules showing 'No Communication' status. Measure CAN bus termination resistance between CAN-H and CAN-L (should read approximately 60 ohms with all modules connected). Check for proper voltage levels: CAN-H and CAN-L should be approximately 2.5V at rest with 1-2V differential during communication.
5. 5

   Inspect Power Distribution Centers
   Locate and inspect both front and rear power distribution centers. Check all fuses and relays for proper seating, corrosion, and continuity. Test fuse integrity even if visually intact. Inspect for signs of overheating including discolored terminals or melted plastic. Verify all power and ground distribution points show proper voltage and less than 0.1V ground resistance when under load.
6. 6

   Evaluate Motor and Inverter Systems
   Review drive unit diagnostic data for both front and rear motors. Check resolver/encoder signals, phase current balance, motor temperatures, and inverter operation. Look for asymmetric phase currents which indicate motor winding issues. Verify motor isolation resistance is within specification (typically greater than 500 megohms). Check for inverter switching faults or over-temperature conditions. Verify motor coolant system operation.
7. 7

   Test Charging System Components
   Inspect onboard charger (OBC) operation and communication. Review charge port status including pilot signal communication, proximity detection, and AC inlet temperature sensors. If DC fast charging issues reported, check CCS protocol communication logs. Verify charge port locking mechanism operates correctly. Test EVSE communication handshake using scan tool monitoring.
8. 8

   Diagnose Specific Symptom Circuit
   Based on customer complaint and DTCs retrieved, isolate the specific circuit or component causing the issue. Use wiring diagrams to trace circuit from control module through connectors to component. Perform voltage, resistance, and continuity tests as appropriate. Check for proper ground connections, voltage supply, and signal integrity. Use oscilloscope to verify signal quality if intermittent issues are suspected.
9. 9

   Inspect Connectors and Wiring
   Physically inspect all connectors related to the fault. Check for bent pins, corrosion, moisture intrusion, or damaged seals. Perform connector pull test to verify proper retention. Inspect wiring harnesses for chafing, damage, or improper routing. Pay special attention to areas where harnesses pass through body panels or near moving components. Check for any aftermarket wiring that may cause interference.
10. 10

    Perform Active Tests and Component Activation
    Use scan tool bi-directional controls to activate suspected components. Test actuators, solenoids, motors, and relays individually to verify operation. Monitor current draw during activation to identify mechanical binding or short circuits. Verify component response matches commanded action. Test sensors by comparing scan tool data to direct measurements with multimeter.
11. 11

    Review Software and Calibration Status
    Check all module software versions against latest available releases. Verify vehicle calibration files are correct for the specific build configuration. Check for any software updates or recalibrations that address the reported concern. Review module configuration and programming status. Verify all modules show proper VIN programming and security access.
12. 12

    Clear Codes and Perform Verification Testing
    After identifying and documenting the fault, clear all diagnostic codes from affected modules. Perform appropriate drive cycle or component operation to verify repair. Monitor live data during test to confirm proper system operation. Verify fault does not return. If intermittent issue, consider extended monitoring or data logging capabilities.

Reassembly

1. Reconnect any connectors that were disconnected during diagnosis
2. Ensure all access panels and covers are properly reinstalled
3. Verify all tools and equipment are removed from vehicle
4. If any high-voltage components were accessed, verify all HV safety covers and shields are properly installed
5. Clear any service mode or diagnostic flags from vehicle systems

Verification

• Perform final complete system scan and verify no DTCs are present or only expected history codes remain
• Verify 12V battery voltage is stable and charging system operates correctly
• Test drive vehicle if appropriate to replicate original customer concern and confirm repair
• Verify all vehicle systems operate normally including propulsion, charging, climate control, and body functions
• Check that all warning lights extinguish after startup and no new faults are generated
• Document all findings, test results, and repair actions in vehicle service history
• If issue was intermittent and not reproduced, provide customer with instructions for monitoring and reporting if symptoms return

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