This procedure covers the inspection, testing, and servicing of the High Voltage Interlock Loop (HVIL) system on the 2022 Rivian EDV 500, ensuring safe operation of the high voltage battery and electrical systems.

Warnings

Tools required

Parts

• HVIL connector seals (if damaged) × 1 — Use OEM specification
• HVIL circuit fuse (if blown) × 1 — Use OEM specification
• High voltage warning labels (if missing or damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in a dry, well-ventilated area away from flammable materials
2. Place wheel chocks at all four wheels and engage parking brake
3. Ensure vehicle is powered OFF and key fob is at least 15 feet away from vehicle
4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for all modules to power down
5. Place high voltage warning signs around vehicle perimeter to warn others
6. Verify all required high voltage safety equipment is present, properly rated, and in good condition
7. Review vehicle service history for any previous high voltage system repairs or warnings
8. Connect diagnostic scan tool and document all existing fault codes before beginning work
9. Verify you have emergency contact information and first aid equipment readily available

Procedure

1. 1

   Access High Voltage Service Disconnect
   Open the hood and locate the High Voltage Service Disconnect (HVSD) located in the front high voltage junction box on the passenger side of the vehicle. Remove the orange protective cover by releasing the locking tabs. This cover is marked with high voltage warning symbols.
   ⚠Ensure vehicle has been powered off for at least 2 minutes before accessing HVSD.
2. 2

   Remove High Voltage Service Disconnect
   Put on high voltage safety gloves. Rotate the HVSD handle counterclockwise approximately 90 degrees until it stops, then pull straight up to remove the disconnect plug. Place the HVSD in a secure location away from the vehicle. Install lockout/tagout device on the HVSD receptacle to prevent accidental reconnection.
   ⚠️Do not touch any high voltage terminals or connectors at this time. Capacitors are still charged.
3. 3

   Wait for Capacitor Discharge
   Wait a minimum of 5 minutes after removing HVSD to allow high voltage capacitors throughout the system to discharge. Set a timer to ensure full wait time. Do not proceed until the full 5 minutes has elapsed.
   ⚠️This wait time is mandatory. Capacitors can hold lethal voltage for several minutes after disconnect.
4. 4

   Verify Zero Voltage
   Using a properly rated high voltage multimeter (1000V CAT III minimum), verify zero voltage at the HVSD terminals. With gloves still on, carefully measure DC voltage between positive and negative terminals, then from each terminal to vehicle ground. All readings must be below 5V DC. Document voltage readings.
   ⚠️If any voltage above 5V is detected, wait an additional 5 minutes and retest. Do not proceed if voltage persists.
5. 5

   Locate HVIL Connectors
   Identify all HVIL connectors throughout the high voltage system. These are typically orange or yellow low-voltage connectors integrated into or adjacent to high voltage orange cable connectors. Key locations include: battery pack main connectors, drive unit power cables, DC fast charge inlet, onboard charger connections, and high voltage junction box connections. Refer to service manual for complete HVIL circuit diagram for EDV 500.
   ℹ️HVIL connectors are separate from high voltage power connectors but are often integrated into the same connector assembly.
6. 6

   Visual Inspection of HVIL System
   Perform thorough visual inspection of all HVIL connectors and wiring. Check for: damaged or corroded connector pins, cracked or damaged connector housings, missing or damaged seals, pinched or chafed HVIL wiring, evidence of water intrusion, loose connections, and proper routing of HVIL wiring. Pay special attention to areas where harnesses pass through bulkheads or near moving components.
   ⚠Even though high voltage is disconnected, handle all components carefully to avoid damage to HVIL circuitry.
7. 7

   Test HVIL Circuit Continuity
   With HVSD still removed, disconnect one HVIL connector (start with battery pack main connector). Using HVIL circuit tester or continuity tester, measure resistance through the HVIL loop. The complete HVIL circuit should show continuity (typically less than 10 ohms) when all connectors are mated. With one connector disconnected, continuity should be lost (open circuit/infinite resistance). Test each HVIL connector individually by disconnecting and checking for open circuit.
   ⚠Use only low voltage test equipment (12V or less) for HVIL circuit testing. Never apply high voltage to HVIL circuits.
8. 8

   Inspect Individual HVIL Connectors
   At each HVIL connector location, disconnect the connector and inspect both halves. Check connector pins for damage, corrosion, or debris. Inspect seal integrity and presence. Verify locking mechanisms function properly. Clean connector pins with electronics-safe contact cleaner if any contamination is present. Use non-metallic brush for stubborn corrosion. Dry thoroughly before reconnection.
   ⚠Do not use compressed air to dry connectors as this can force moisture deeper into connector cavities.
9. 9

   Service or Replace Damaged Components
   Replace any damaged HVIL connector seals, repair or replace damaged wiring per Rivian service procedures, and replace any HVIL connectors showing signs of heat damage, severe corrosion, or damaged pins. If HVIL circuit fuse is found blown during testing, identify and repair root cause before replacing fuse. Apply thin coat of dielectric grease to connector seals (not pins) to aid in sealing and prevent corrosion.
   ⚠Never attempt to repair HVIL connector pins. Replace entire connector assembly if pins are damaged.
10. 10

    Reconnect HVIL Connectors
    Reconnect all HVIL connectors in reverse order of disconnection. Ensure each connector seats fully with audible click. Verify locking tabs engage properly. Gently tug on each connector to confirm secure connection. Route all HVIL wiring properly per service manual specifications, ensuring no pinch points or interference with moving parts.
    ⚠Partially seated HVIL connectors will cause system faults and prevent vehicle operation.
11. 11

    Final HVIL Circuit Test
    With all HVIL connectors reconnected but HVSD still removed, perform final continuity test of complete HVIL loop. Circuit should show proper continuity (less than 10 ohms resistance). Verify no shorts to ground by testing between HVIL circuit and vehicle chassis ground (should read open circuit/infinite resistance). Document all test results.
    ⚠If HVIL circuit does not show proper continuity, do not proceed. Recheck all connections and repeat inspection.
12. 12

    Reinstall High Voltage Service Disconnect
    Remove lockout/tagout device. With high voltage gloves on, align HVSD plug with receptacle and insert straight down until fully seated. Rotate handle clockwise 90 degrees until it locks in place. You should feel definite resistance and hear/feel a click when properly seated. Reinstall orange protective cover, ensuring locking tabs engage fully.
    ⚠HVSD must be fully seated and locked. Partial engagement will prevent system operation and may cause arcing.
13. 13

    Reconnect 12V Battery and Initialize System
    Reconnect 12V auxiliary battery negative terminal. Wait 30 seconds for vehicle systems to initialize. Using diagnostic scan tool, wake up vehicle systems and check for any high voltage system fault codes. HVIL circuit faults should not be present if service was performed correctly. Document all fault codes present.
    ℹ️Some fault codes may require manual clearing even after successful repair. Follow diagnostic scan tool procedures.
14. 14

    Perform System Verification
    With key fob present, power on vehicle to READY mode (do not enable drive yet). Verify high voltage system activates properly on scan tool. Check that battery voltage is present (typically 350-420V DC depending on state of charge). Monitor for any new fault codes during power-up sequence. Verify all high voltage warning lights illuminate during bulb check and then extinguish.
    ⚠If high voltage system does not activate or fault codes appear, power down immediately and reinspect work.
15. 15

    Final Testing and Documentation
    Perform a complete vehicle systems test using diagnostic scan tool. Test drive vehicle in a safe area to verify normal operation of both drive motors under light load. Monitor for any unusual behavior, warning lights, or performance issues. Return to service bay and perform final scan for fault codes. Document all work performed, test results, parts replaced, and final system status in vehicle service records.
    ⚠If any abnormal operation is detected during test drive, discontinue immediately and perform additional diagnostics.

Reassembly

1. Ensure all high voltage connector protective covers are properly installed
2. Verify all access panels and covers removed during service are reinstalled
3. Remove all high voltage warning signs and barriers from around vehicle
4. Clean work area and properly dispose of any replaced parts per regulations for high voltage components
5. Update vehicle service records with complete documentation of HVIL service performed

Verification

• Confirm no high voltage system fault codes are present after service completion
• Verify HVIL circuit shows proper continuity (less than 10 ohms) through complete loop
• Confirm high voltage system activates to READY mode without issues
• Verify battery pack voltage is present and within normal range (350-420V DC)
• Test drive vehicle and confirm both drive motors operate normally under load
• Perform final diagnostic scan and verify no new fault codes have appeared
• Confirm all HVIL connectors are properly seated with locking tabs engaged
• Verify HVSD is fully installed, locked, and protective cover is in place
• Document that all high voltage safety procedures were followed throughout service

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