This procedure covers the removal and replacement of the ABS pump/module assembly on the 2023 Rivian EDV 500 electric delivery van, including brake system bleeding and verification.

Warnings

Tools required

Parts

• ABS pump/module assembly × 1 — Use OEM specification
• Brake line sealing washers × 6 — Use OEM specification
• ABS module mounting hardware × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery using battery disconnect tool and wait minimum 10 minutes for system capacitor discharge
3. Verify high-voltage system is de-energized by checking instrument cluster displays are off
4. Open hood and remove front underbody panel to access ABS module location
5. Place drain pan under ABS module area to catch brake fluid
6. Remove front bumper cover or wheel well liner as needed for access to brake lines
7. Clean area around ABS module with brake cleaner to prevent contamination during disassembly

Procedure

1. 1

   Disconnect electrical connectors
   Locate the ABS module electrical connectors on the driver side of the module. Press the red connector release tabs and carefully disconnect all electrical connectors from the ABS pump assembly. Tag or photograph connections for proper reassembly. Inspect connectors for corrosion or damage.
2. 2

   Evacuate brake fluid from ABS module
   Using a brake fluid evacuation pump, draw as much brake fluid as possible from the ABS module reservoir to minimize spillage during line disconnection. Position drain pan directly beneath the module to catch remaining fluid.
3. 3

   Disconnect brake lines from ABS module
   Using appropriate flare nut wrenches, carefully loosen and disconnect all six brake lines from the ABS module. Work slowly to avoid rounding off fittings. Label each line with its position (LF, RF, LR, RR, master cylinder inlet, master cylinder outlet) using tape. Cap open lines immediately to prevent contamination and fluid loss.
4. 4

   Remove ABS module mounting fasteners
   Locate and remove all ABS module mounting bolts. The module is typically secured with four mounting bolts to the frame bracket. Support the module weight while removing the final fastener as the unit weighs approximately 8-10 pounds when full of fluid.
5. 5

   Remove ABS pump assembly
   Carefully lower and remove the ABS pump/module assembly from the vehicle. Keep unit upright to minimize fluid spillage. Inspect mounting bracket and surrounding area for corrosion or damage. Clean mounting surface thoroughly with brake cleaner.
6. 6

   Prepare new ABS module
   Remove new ABS module from packaging. Verify part number matches original unit. Inspect all electrical connectors and brake line ports for shipping plugs or protective covers. Remove protective covers just before installation. Do not remove port caps until immediately before connecting brake lines.
7. 7

   Install new ABS module
   Position new ABS module onto mounting bracket, ensuring proper orientation and alignment. Install mounting bolts and tighten in a cross pattern to ensure even seating against bracket. Hand-tighten initially, then proceed to secure fasteners.
8. 8

   Connect brake lines to ABS module
   Install new sealing washers on each brake line fitting. Connect brake lines to corresponding ports on ABS module using line labels from disassembly. Thread fittings by hand first to ensure proper engagement, then tighten with flare nut wrench. Use two-wrench method to prevent component damage - hold module port stationary while tightening line fitting.
9. 9

   Reconnect electrical connectors
   Carefully reconnect all electrical connectors to the ABS module, ensuring each connector seats fully and locks into place with an audible click. Verify connector retention by gently pulling on each connection. Route wiring harnesses away from sharp edges and heat sources.
10. 10

    Fill brake fluid reservoir
    Locate master cylinder reservoir and fill with fresh DOT 4 brake fluid to MAX line. Throughout bleeding process, monitor reservoir level constantly and maintain above MIN line to prevent air introduction into system.
11. 11

    Perform manual brake bleeding
    Bleed brake system at all four wheels in proper sequence (typically RR, LR, RF, LF for this vehicle). Use pressure bleeder or two-person manual bleeding method. At each wheel, attach clear hose to bleeder screw, open bleeder, and allow fluid to flow until no air bubbles are visible. Close bleeder before releasing brake pedal. Repeat until firm pedal is achieved.
12. 12

    Reconnect battery and perform ABS module initialization
    Reconnect 12V battery. Connect Rivian diagnostic scanner to vehicle OBDII port. Follow scanner prompts to initialize new ABS module and register component with vehicle control systems. This step programs the module to communicate with vehicle network.
13. 13

    Perform electronic ABS bleeding procedure
    Using Rivian diagnostic scanner, initiate ABS automated bleeding procedure. This cycles ABS solenoids and pump to purge air from internal passages that cannot be reached through manual bleeding. Follow all scanner prompts. Procedure typically cycles pump 3-5 times. Monitor brake fluid reservoir and refill as needed during this process.
14. 14

    Final brake fluid top-off and inspection
    Fill brake fluid reservoir to MAX line with fresh DOT 4 fluid. Inspect all brake line connections at ABS module for leaks. Wipe connections clean and observe for several minutes. Check brake pedal feel - should be firm with no sponginess. If pedal is soft, repeat bleeding procedures.

Reassembly

1. Reinstall front bumper cover, wheel well liner, and underbody panels removed during disassembly
2. Verify all electrical connectors are fully seated and locked
3. Ensure all tools and materials are removed from engine compartment
4. Double-check brake fluid reservoir level is at MAX line with fresh DOT 4 fluid

Verification

• Start vehicle and verify ABS warning light illuminates during bulb check then extinguishes within 3-5 seconds
• Use diagnostic scanner to verify no ABS fault codes are present in system
• Perform brake pedal test - pedal should be firm with approximately 1-2 inches of travel before resistance
• Test drive vehicle in safe area at low speed (under 10 mph) and verify normal brake operation
• Perform ABS self-test using diagnostic scanner or by performing controlled ABS stop on appropriate surface if scanner function available
• After test drive, re-inspect all brake line connections at ABS module for signs of leakage
• Verify brake fluid level has not dropped - any decrease indicates leak or insufficient bleeding
• Document ABS module part number and installation date for vehicle service records

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