This procedure covers the removal and replacement of the DC-DC converter on a 2023 Rivian EDV 500, which converts high-voltage battery power to 12V for vehicle accessories.

Warnings

Tools required

Parts

• DC-DC Converter Assembly × 1 — Use OEM Rivian part
• High-voltage connector seals × 2 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification
• DC-DC converter mounting hardware kit × 1 — Use OEM specification
• High-voltage interlock connector × 1 — If damaged during removal

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow high-voltage system to cool
3. Connect Rivian diagnostic tool and document any existing fault codes
4. Verify 12V battery is fully charged (system will need 12V power for certain procedures)
5. Place high-voltage warning signs around vehicle work area
6. Put on high-voltage safety gloves and ensure insulated tools are ready
7. Position coolant drain pan under front of vehicle near DC-DC converter location
8. Remove front under-shield panels to access DC-DC converter compartment

Procedure

1. 1

   Disable High-Voltage System
   Using Rivian diagnostic software, initiate high-voltage disconnect procedure. Disconnect 12V auxiliary battery negative terminal. Locate high-voltage service disconnect (under rear cargo area) and rotate counterclockwise to remove. Store disconnect plug in a secure location away from vehicle. Wait minimum 15 minutes for capacitor discharge.
2. 2

   Verify Zero Voltage
   Using a calibrated high-voltage multimeter, verify zero voltage at the high-voltage busbar connections. Check voltage between HV+ and HV- terminals at the DC-DC converter input. Voltage must read less than 5V DC before proceeding. Document voltage readings.
3. 3

   Drain Coolant System
   Locate coolant drain valve on the thermal management system near the DC-DC converter. Attach drain hose to valve and route to drain pan. Open drain valve and allow coolant to drain until flow stops. Close drain valve. Note the amount of coolant drained for refill reference.
4. 4

   Disconnect Low-Voltage Connections
   Remove protective cover from DC-DC converter 12V output terminal. Disconnect 12V positive cable from output terminal and secure away from work area. Disconnect low-voltage control harness connector by pressing release tab and pulling straight out. Label all connections for reassembly reference.
5. 5

   Disconnect Coolant Lines
   Using hose clamp pliers, release spring clamps on coolant inlet and outlet hoses at DC-DC converter. Carefully twist and pull hoses straight off fittings. Be prepared for residual coolant spillage. Plug hose ends and converter fittings with clean shop towels to prevent contamination.
6. 6

   Remove High-Voltage Interlock
   Locate the orange high-voltage interlock connector on the DC-DC converter housing. Press the safety lock tab and disconnect the interlock connector. This connector ensures the high-voltage connection cannot be made unless properly seated. Inspect connector and pins for damage.
7. 7

   Disconnect High-Voltage Cables
   Remove protective orange covers from high-voltage positive and negative terminals. Using insulated tools, remove mounting bolts securing HV cables to converter terminals. Carefully lift cables away from terminals and secure with non-conductive support. Cover exposed terminals with insulating caps.
8. 8

   Remove Mounting Brackets
   Locate and remove the three mounting brackets securing DC-DC converter to vehicle frame. Remove upper bracket bolts first, then side brackets. Support converter weight with battery support stand before removing final mounting points.
9. 9

   Remove DC-DC Converter
   With all connections and mounts disconnected, carefully lower DC-DC converter using support stand. Guide converter away from vehicle, being careful not to damage surrounding components or harnesses. Place converter on clean work surface for inspection or disposal according to manufacturer guidelines.
10. 10

    Prepare New DC-DC Converter
    Unpack new DC-DC converter and verify part number matches vehicle specifications. Inspect all terminals, coolant fittings, and mounting points for shipping damage. Install new high-voltage connector seals if provided with replacement unit. Verify interlock connector is properly seated in housing.
11. 11

    Install DC-DC Converter
    Position new DC-DC converter on support stand and carefully lift into mounting location. Align mounting brackets with frame mounting points. Install mounting bracket bolts and tighten in a cross pattern to ensure even seating. Verify converter is securely mounted and properly aligned with all connection points.
12. 12

    Connect High-Voltage Cables
    Remove insulating caps from high-voltage terminals. Using insulated tools, position HV+ cable on positive terminal first, then HV- cable on negative terminal. Install mounting bolts and tighten to specification. Ensure cables are properly seated with no gaps between terminal and cable lug. Install protective orange terminal covers.
13. 13

    Connect High-Voltage Interlock
    Connect orange high-voltage interlock connector to DC-DC converter housing. Ensure connector clicks fully into place and safety lock tab engages. Gently tug on connector to verify secure connection. This must be properly connected or high-voltage system will not activate.
14. 14

    Connect Coolant Lines
    Remove plugs from coolant hoses and converter fittings. Install coolant inlet hose on inlet fitting first, ensuring hose is fully seated over fitting barb. Install new spring clamp. Repeat for outlet hose. Verify hoses are routed properly without kinks or interference with other components.
15. 15

    Connect Low-Voltage Connections
    Connect low-voltage control harness to DC-DC converter, ensuring connector clicks into place. Connect 12V positive output cable to converter output terminal and tighten to specification. Install protective cover over 12V terminal. Double-check all low-voltage connections are secure.

Reassembly

1. Reinstall front under-shield panels and secure all fasteners
2. Reconnect 12V auxiliary battery negative terminal
3. Refill coolant system with specified EV Battery/Motor Coolant through fill port, approximately 2 quarts or until level is correct
4. Bleed air from coolant system using Rivian diagnostic software cooling system purge procedure
5. Reinstall high-voltage service disconnect plug and rotate clockwise until locked
6. Remove high-voltage warning signs from work area

Verification

• Using Rivian diagnostic software, enable high-voltage system and verify DC-DC converter activation
• Check for any fault codes related to DC-DC converter or high-voltage system
• Verify 12V system voltage is between 13.5-14.5V with vehicle in ready mode
• Monitor DC-DC converter output voltage and current using diagnostic software to ensure proper operation
• Inspect all coolant connections for leaks with system at operating temperature
• Verify thermal management system is circulating coolant through DC-DC converter
• Check high-voltage terminal connections for proper seating and no signs of arcing
• Perform test drive and monitor DC-DC converter operation under various loads
• Re-check all connections and coolant level after test drive
• Clear any temporary fault codes and verify no new codes are present

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