This procedure covers the removal and replacement of a high voltage battery module in a 2022 Rivian EDV 500 electric delivery van, requiring complete high voltage system isolation and specialized safety equipment.

Warnings

Tools required

Parts

• High voltage battery module × 1 — Use OEM specification - module specific to pack position
• Battery module thermal interface pad × 1 — Use OEM specification
• High voltage connector seals × 2 — Use OEM specification
• Battery module mounting hardware kit × 1 — Use OEM specification
• Coolant hose O-rings × 4 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Ensure vehicle is on a level surface with parking brake applied and wheel chocks in place
2. Verify high voltage insulated gloves are in current test date and have no visible damage
3. Place high voltage warning signs around vehicle work area and restrict access
4. Connect Rivian diagnostic tool and document any existing fault codes related to battery system
5. Note the specific module position requiring replacement from diagnostic system
6. Ensure fire extinguisher rated for electrical fires (Class C) is readily accessible
7. Remove 12V auxiliary battery negative terminal and wait 5 minutes for system shutdown
8. Remove lower belly pan and underbody panels to access high voltage battery pack
9. Identify and photograph all coolant line routing for reassembly reference

Procedure

1. 1

   Perform high voltage lockout/tagout procedure
   Using diagnostic tool, command the battery management system to safe mode. Locate the high voltage service disconnect (typically under rear cargo area access panel). Don high voltage gloves with leather protectors. Remove service disconnect cover, then pull and remove the high voltage service disconnect plug. Install lockout device on disconnect and place tag. Store disconnect plug in secure location away from vehicle.
2. 2

   Wait and verify voltage discharge
   Wait minimum 15 minutes for high voltage system capacitors to fully discharge. After waiting period, use calibrated high voltage multimeter to verify 0V DC across all high voltage bus bars and connections within the battery pack. Document voltage readings. Do not proceed until verified safe.
3. 3

   Drain battery cooling system
   Place drain pan (minimum 3 gallon capacity) beneath battery pack coolant drain location. Locate battery coolant drain valve on battery pack underbody. Open drain valve and allow coolant to fully drain. Collect and properly dispose of used coolant. Close drain valve when complete. Note: Some coolant will remain in individual modules.
4. 4

   Disconnect battery pack coolant lines
   Identify coolant quick-connect fittings at the battery pack inlet and outlet. Have shop towels ready to catch residual coolant. Press release tabs and disconnect coolant lines from battery pack. Cap or plug open lines to prevent contamination. Inspect O-rings for damage and note for replacement during reassembly.
5. 5

   Remove battery pack upper cover
   From inside cargo area, remove cargo floor panels to access battery pack upper cover. Remove all fasteners securing upper battery cover (typically 16-20 bolts around perimeter). Carefully lift upper cover away, noting orientation and position of any wiring harnesses or vent tubes. Set cover aside in protected area.
6. 6

   Disconnect high voltage module connections
   Wearing high voltage gloves, locate the faulty battery module identified in preparation. Identify high voltage busbars connected to module terminals. Remove busbar fasteners (typically 10mm bolts). Carefully lift busbars away from module terminals without bending. Cover exposed terminals with insulating material to prevent accidental contact.
7. 7

   Disconnect module coolant and sensor connections
   Locate coolant inlet and outlet quick-connects on the battery module. Have towels ready for residual coolant spillage. Press release tabs and disconnect coolant lines from module. Disconnect module temperature sensor connector and any module voltage sense connectors. Label all connections for correct reassembly.
8. 8

   Remove battery module mounting hardware
   Identify all mounting brackets and fasteners securing the battery module to the pack structure. Typical configuration includes 4-6 mounting bolts and retention brackets. Remove mounting hardware and set aside for inspection. Note exact mounting bolt positions and any spacers or washers used.
9. 9

   Extract battery module from pack
   Position battery lift table or suitable jack beneath the battery module. The module weighs approximately 50-70 lbs. Support module weight with lift device. Carefully slide module horizontally out of pack structure, ensuring no high voltage connections or coolant lines are snagged. Lower module onto lift table and remove from under vehicle. Handle module with care to avoid impact or puncture damage.
10. 10

    Prepare battery pack for new module installation
    Inspect module mounting area within battery pack for any coolant leaks, debris, or damage. Clean all mounting surfaces with lint-free cloth and isopropyl alcohol. Inspect busbar connection points for corrosion or damage. Verify coolant passages are clear and undamaged. Check thermal interface mounting surface is clean and flat.
11. 11

    Install thermal interface material on new module
    Remove protective film from new battery module. Apply new thermal interface pad to bottom of module per manufacturer specifications, ensuring complete coverage and no air bubbles. If using thermal paste instead of pad, apply thin even coat (approximately 0.5mm thickness) to module thermal contact surface.
12. 12

    Install new battery module into pack
    Place new battery module on lift table and position under vehicle. Raise module to approximate installation height. Carefully slide module horizontally into battery pack structure, aligning with mounting brackets and ensuring thermal interface contacts pack cooling plate. Verify module is fully seated and aligned with mounting holes.
13. 13

    Install module mounting hardware
    Install all mounting brackets and fasteners to secure battery module to pack structure. Apply medium strength thread locking compound to mounting bolt threads as specified by manufacturer. Install mounting bolts with any spacers or washers in original configuration. Tighten mounting hardware in cross-pattern sequence to ensure even clamping force. Note: Torque specifications not available in database - consult Rivian service manual for exact values.
14. 14

    Reconnect module coolant and sensor connections
    Install new O-rings on module coolant fittings, lubricating lightly with coolant. Connect coolant inlet and outlet lines to module, ensuring quick-connects fully engage with audible click. Tug gently to verify secure connection. Reconnect module temperature sensor connector and voltage sense connectors per labels made during disassembly.
15. 15

    Reconnect high voltage module connections
    Wearing high voltage gloves, remove insulating covers from module terminals. Install new connector seals if specified. Position high voltage busbars onto module terminals, ensuring proper alignment and full contact. Install and tighten busbar fasteners. Note: Torque specifications not available in database - consult Rivian service manual for critical high voltage connection torque values. Verify all connections are secure and properly seated.
16. 16

    Reinstall battery pack upper cover
    Position battery pack upper cover, aligning any vent tubes or wiring harnesses. Install all cover fasteners in cross-pattern sequence. Ensure cover seals properly around entire perimeter. Verify no wiring or components are pinched by cover.
17. 17

    Reconnect battery pack coolant system
    Remove caps from battery pack coolant line connections. Install new O-rings on coolant quick-connect fittings. Connect coolant inlet and outlet lines to battery pack, ensuring full engagement with audible click. Verify secure connection by gentle pull test.
18. 18

    Refill battery cooling system
    Fill battery cooling system with specified EV Battery/Motor Coolant through fill port. Add coolant slowly to allow air to escape. Follow Rivian bleeding procedure to remove all air from system. Fill to proper level per service manual specifications. Run coolant pump test cycle if available via diagnostic tool to circulate coolant and verify no leaks.
19. 19

    Restore high voltage system
    Wearing high voltage gloves, retrieve high voltage service disconnect plug from secure storage. Remove lockout/tagout device. Inspect disconnect plug contacts for any damage or corrosion. Insert service disconnect plug fully into receptacle until seated. Install service disconnect cover. Reconnect 12V auxiliary battery negative terminal.
20. 20

    Commission new battery module
    Connect Rivian diagnostic tool and power on vehicle. Follow battery management system commissioning procedure to register new module. This typically includes module identification, capacity learning, and cell balancing initialization. Clear any fault codes related to the module replacement. Verify battery management system recognizes all modules with correct parameters.

Reassembly

1. Reinstall all underbody panels and belly pan with proper fasteners and torque
2. Reinstall cargo floor panels and interior trim components
3. Verify all coolant connections show no signs of leakage
4. Ensure all tools and materials are removed from vehicle and work area
5. Remove high voltage warning signs from work area

Verification

• Using diagnostic tool, verify battery management system reports all modules online with no fault codes
• Check battery state of charge and verify all cell voltages are within normal range (typically within 0.02V of each other)
• Verify coolant level is correct and no leaks are present at any connections after system pressure test
• Perform a low-power test drive to verify battery pack operates normally without warnings
• Monitor battery temperatures during charging cycle to ensure cooling system functions properly
• Verify high voltage service disconnect is properly secured and lockout device is removed
• Confirm 12V auxiliary battery is reconnected and vehicle electrical systems function normally
• Document all work performed, including module serial numbers, position, and commissioning data

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