High Voltage Battery Pack R&R

Complete removal and replacement of the high voltage battery pack assembly on the Rivian EDV 500 commercial van, including disconnection of all high voltage systems, coolant lines, and structural fasteners.

Warnings

Tools required

Parts

• High voltage battery pack assembly × 1 — Use OEM specification
• Battery pack coolant seal kit × 1 — Use OEM specification
• HV connector seals (if damaged) × 1 — Use OEM specification
• Underbody panel clips × 20 — Replace as needed
• Battery retention bolt seals × 12 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Ensure vehicle is on level surface with parking brake engaged and wheels chocked
2. Verify service bay is clear of all flammable materials and has appropriate fire suppression equipment rated for lithium-ion battery fires (Class D extinguisher)
3. Confirm high voltage safety equipment (insulated gloves, face shield, multimeter) is in good condition and properly rated
4. Allow vehicle to sit powered off for minimum 2 hours to allow coolant system to depressurize and cool
5. Document battery state of charge (SOC) - target 30-50% SOC for safest handling
6. Photograph all connector orientations and routing before disassembly
7. Prepare battery pack support fixture or transmission jack with proper padding to distribute load
8. Review Rivian service manual emergency procedures for battery thermal events

Procedure

1. 1

   Disable high voltage system
   Open driver's door and access 12V service disconnect under driver's seat by removing access panel. Disconnect 12V battery negative terminal. Wait 5 minutes for all vehicle systems to power down completely. Access HV service disconnect located in rear cargo area behind driver-side panel. Wearing insulated gloves, rotate HV service disconnect counterclockwise and remove. Install lockout/tagout device. Place removed disconnect in secure location away from vehicle.
   ⚠️Verify vehicle is completely powered down - no displays, no sounds - before proceeding to HV disconnect.
2. 2

   Verify high voltage isolation
   Wait minimum 15 minutes after HV disconnect removal. Using calibrated high voltage multimeter with insulated gloves still worn, measure voltage between HV positive and chassis ground, then HV negative and chassis ground. Both readings must be below 5V DC. If voltage exceeds 5V, wait additional 10 minutes and retest. Do not proceed until voltage is safe. Document voltage readings.
   ⚠️If voltage does not drop below 5V after 30 minutes total wait time, battery pack has internal fault. Do not proceed - contact Rivian technical support.
3. 3

   Raise vehicle and remove underbody panels
   Raise vehicle on lift to comfortable working height. Remove all underbody aerodynamic panels beneath battery pack area (approximately 8-10 panels depending on configuration). Store panels and fastener clips separately. Remove rear skid plate if equipped. This exposes battery pack retention bolts and coolant connections.
   ⚠Support vehicle on lift safety locks. Never rely solely on hydraulic lift pressure when working beneath vehicle.
4. 4

   Drain battery coolant system
   Locate battery coolant drain valve on driver-side front corner of battery pack. Place drain pan beneath valve. Slowly open drain valve and allow coolant to drain completely (approximately 10 quarts). Once drained, close drain valve. Label and disconnect coolant supply and return lines from battery pack using appropriate line disconnect tools. Cap open lines to prevent contamination.
   ⚠Coolant may still be warm. Wear protective gloves and eye protection.
5. 5

   Disconnect high voltage power cables
   Wearing insulated gloves, locate HV main power connectors at front of battery pack (orange cables). Remove protective covers. Using insulated tools, remove retaining bolts from positive and negative HV bus bar connections. Carefully separate connectors and secure cables away from battery pack using non-conductive zip ties. Cover exposed terminals with insulating caps.
   ⚠️Even with system disabled, treat all orange cables as energized. Never allow tools to bridge positive and negative terminals.
6. 6

   Disconnect low voltage and communication harnesses
   Locate battery management system (BMS) connector on top surface of battery pack, accessible from underneath. Release connector locking tab and carefully disconnect. Disconnect all remaining low voltage connectors including temperature sensors, contactors, and communication lines. Total of 4-6 connectors depending on configuration. Mark each connector location for reinstallation.
7. 7

   Position battery pack support fixture
   Position battery pack support fixture or heavy-duty transmission jack directly beneath center of battery pack. Adjust height until support pads make firm contact with battery pack lifting points (marked with yellow triangles on pack underside). Ensure load is evenly distributed across all support points. Secure battery pack to fixture with retention straps if available.
   ⚠️Battery pack weighs approximately 1,200 lbs. Verify support fixture is rated for minimum 1,500 lb capacity and is stable before removing retention bolts.
8. 8

   Remove battery pack retention bolts
   Locate battery pack retention bolts around perimeter of pack (typically 16-20 bolts). Working in cross-pattern from center outward, loosen all bolts 2-3 turns each. Once all bolts are loose, remove bolts completely, working from rear to front. Keep bolts organized by location. Battery pack is now held only by support fixture.
   ⚠Have second technician monitor battery pack stability during bolt removal. Pack may shift as bolts are removed.
9. 9

   Lower and remove battery pack
   With second technician assisting, slowly and carefully lower battery pack support fixture. Monitor all clearances as pack descends, particularly HV cable routing and any remaining wire harnesses. Lower pack completely to ground. Once stable, disconnect any remaining ground straps. Carefully transport battery pack away from vehicle to secure storage area using appropriate material handling equipment.
   ⚠️Lower pack slowly - maximum 2 inches per minute. Stop immediately if resistance is felt or unusual sounds occur.
   ⚠Store removed battery pack on flat, non-conductive surface away from heat sources, moisture, and flammable materials.
10. 10

    Inspect vehicle and prepare for installation
    With battery pack removed, inspect battery mounting area in vehicle chassis. Clean all mounting surfaces, bolt holes, and ground contact points. Check for any damage, corrosion, or debris. Inspect all coolant line fittings for damage. Verify HV cable routing guides and grommets are intact. Clean and inspect all electrical connectors.
11. 11

    Install replacement battery pack
    Position replacement battery pack on support fixture in same orientation as removed pack. Verify all new seals are installed per seal kit instructions. Carefully raise battery pack into position, aligning with mounting holes and guide pins. Have second technician guide pack and monitor clearances. Raise until pack is approximately 1/4 inch from final seated position.
    ⚠Verify replacement battery pack part number matches vehicle specification and has appropriate firmware version.
12. 12

    Install retention bolts and reconnect systems
    Install all battery pack retention bolts finger-tight, starting from front and working rearward. Once all bolts are started, torque in cross-pattern per Rivian specifications (specifications not provided - consult service manual). Reconnect all low voltage connectors in reverse order of removal, ensuring positive engagement. Reconnect HV power cables to bus bars with new seals, ensuring proper torque (consult service manual). Reconnect battery coolant lines with new seals.
    ℹ️Critical torque specifications not available in database. Consult official Rivian service documentation for exact torque values - improper torque can cause HV system failure.
13. 13

    Refill coolant system
    Using fresh EV battery/motor coolant meeting Rivian specifications, refill battery cooling system through fill port. Fill slowly to avoid air pockets. Total capacity approximately 10 quarts. Once filled to proper level, install fill cap. Check all coolant connections for proper seating.
14. 14

    Reinstall underbody panels and lower vehicle
    Reinstall rear skid plate if equipped. Reinstall all underbody aerodynamic panels in reverse order of removal using new clips where needed. Ensure all panels are properly aligned and secured. Lower vehicle to ground.
15. 15

    Restore high voltage system and initialize
    Reinstall HV service disconnect and rotate clockwise until fully seated. Reconnect 12V battery negative terminal. Remove lockout/tagout device. Using Rivian diagnostic software, perform battery pack initialization procedure, clear any stored fault codes, and verify all battery management system parameters are within specification. Perform HV isolation test using diagnostic software - must show greater than 500 ohms isolation resistance.
    ⚠️If HV isolation test fails, immediately disable HV system and inspect all connections. Do not operate vehicle with isolation fault.

Reassembly

1. All retention bolts must be torqued to Rivian specifications - improper torque can cause battery pack detachment or HV connector failure
2. Verify all coolant connections are tight and properly sealed before system pressurization
3. Ensure all HV cable routing matches original configuration with proper clearances and no pinch points
4. All underbody panels must be properly installed to maintain vehicle aerodynamics and water protection
5. Perform final walk-around inspection to verify no tools or parts remain in battery pack area

Verification

• Using Rivian diagnostic software, verify battery pack is communicating properly and all cell voltages are balanced within 0.010V
• Confirm no diagnostic trouble codes (DTCs) related to HV system, battery management, or cooling system
• Verify HV isolation resistance test shows >500 ohms between HV system and chassis ground
• Check battery state of charge (SOC) is reading correctly and matches expected value
• Perform stationary coolant system pressure test - should hold pressure with no leaks for 5 minutes
• With vehicle powered on (ready mode), verify battery cooling system activates and coolant circulates (check coolant temperature rise)
• Test drive vehicle minimum 10 miles, monitoring battery temperatures, power delivery, and regenerative braking function
• After test drive, perform thermal imaging scan of battery pack to verify no hot spots or abnormal temperature distribution
• Re-check all accessible HV and coolant connections for signs of leakage or loosening after test drive
• Document final battery pack serial number, installation date, and initial state of health in vehicle service records

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