This procedure performs a complete EV system reset and calibration for the Rivian EDV 500, including high-voltage system diagnostics, battery management system recalibration, motor controller reset, and sensor relearning procedures.

Warnings

Tools required

Parts

• High-voltage interlock connector seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in a well-ventilated area with adequate clearance around vehicle
2. Ensure battery state of charge is between 20-80% for optimal calibration
3. Verify no active fault codes related to high-voltage battery, motor controllers, or charging system
4. Place HV warning signs around vehicle work area
5. Connect 12V battery maintainer to prevent low-voltage system disruption during procedure
6. Ensure all doors, windows, hood, and cargo areas are closed
7. Verify tire pressures are set to specification (check door jamb label)
8. Ensure vehicle has been stationary for at least 30 minutes with HVAC system off

Procedure

1. 1

   Initial System Scan and Documentation
   Connect diagnostic software to OBD-II port located under driver side dashboard. Power on vehicle to accessory mode (do not press brake pedal). Perform full system scan and document all existing fault codes, freeze frame data, and current calibration versions for BMS, motor controllers, and power distribution module. Save baseline data file for comparison after reset.
2. 2

   12V Battery Isolation
   Open front hood. Locate 12V auxiliary battery in front compartment driver side. Using 10mm socket, disconnect negative terminal first, then positive terminal. Wait 5 minutes to allow all vehicle control modules to fully discharge capacitors and enter sleep mode. This ensures complete system reset.
   ℹ️Battery maintainer will disconnect automatically. This is normal.
3. 3

   High-Voltage System Access
   Don high-voltage safety gloves. Open rear cargo area and remove lower floor panel to access HV battery disconnect location. Locate orange manual service disconnect (MSD) on right side of battery pack. Rotate MSD handle 90 degrees counterclockwise and pull straight out to remove. Store MSD in front seat to prevent reinsertion. Wait 5 minutes for high-voltage capacitors to discharge.
   ⚠️Never bypass or defeat the manual service disconnect. This is the primary safety isolation for the HV system.
4. 4

   High-Voltage System Verification
   Using CAT III rated multimeter, verify zero voltage at HV battery terminals and motor controller inputs. Check DC voltage between positive and negative HV bus bars at battery pack - reading must be below 5V DC. Check voltage from each HV bus bar to vehicle chassis ground - both readings must be below 5V DC. Document all readings.
   ⚠️If any voltage above 5V DC is detected, wait additional 10 minutes and re-test. Do not proceed if voltage remains present.
5. 5

   HV Connector Inspection
   Visually inspect all accessible high-voltage connectors (orange cables) for damage, corrosion, or moisture intrusion. Check interlock connections at MSD location for proper seating and seal condition. Inspect HV battery coolant connections for leaks. Replace any damaged seals or connectors before proceeding.
6. 6

   12V System Reconnection
   Reconnect 12V auxiliary battery: positive terminal first, then negative terminal. Ensure connections are clean and tight. Do not power on vehicle yet. Reconnect battery maintainer and verify 12.5V or higher at battery terminals with multimeter.
7. 7

   Initial Power-Up and Clear Codes
   With MSD still removed and HV system isolated, press brake pedal and power button to enter accessory mode. Connect diagnostic software. Clear all stored fault codes from all modules. Power off vehicle completely. Wait 30 seconds.
8. 8

   High-Voltage System Reconnection
   Don HV gloves. Inspect MSD for damage to contacts or housing. Insert MSD fully into battery pack receptacle until it seats completely, then rotate handle 90 degrees clockwise to lock. Verify interlock indicator shows proper engagement. Replace floor panel in cargo area.
   ⚠High-voltage system will re-energize once MSD is installed and locked.
9. 9

   Battery Management System Calibration
   Power vehicle to accessory mode. Using diagnostic software, navigate to BMS module. Execute 'BMS Reset and Calibration' procedure. This will reset cell voltage mapping, temperature sensor calibration, and state-of-charge algorithms. Process takes approximately 15-20 minutes. Do not interrupt. Monitor progress on diagnostic screen.
   ⚠Vehicle may display battery warnings during calibration. This is normal and codes will clear upon completion.
10. 10

    Motor Controller Calibration
    In diagnostic software, navigate to front motor controller module. Execute 'Motor Controller Reset and Position Sensor Calibration'. Repeat identical procedure for rear motor controller. Each calibration takes 5-8 minutes. Software will command motors through specific position sequences - motors may make brief clicking or humming sounds during this process.
11. 11

    Power Distribution Module Reset
    Navigate to Power Distribution Module (PDM) in diagnostic software. Execute 'PDM Configuration Reset'. This resets all high-voltage contactor settings, pre-charge resistor parameters, and DC-DC converter calibration. Process takes 3-5 minutes.
12. 12

    Brake System Calibration
    Navigate to brake control module. Execute 'Regenerative Brake Blend Calibration'. This resets the coordination between regenerative braking and friction braking. With parking brake released, software will command brake actuator through test sequence. Brake pedal may move slightly during calibration.
13. 13

    Steering Angle and Vehicle Dynamics Reset
    Navigate to steering angle sensor module. Verify wheels are pointing straight ahead. Execute 'Steering Angle Sensor Zero Point Calibration'. Then navigate to vehicle dynamics module and execute 'Yaw Rate and Lateral Acceleration Sensor Calibration'. Vehicle must remain stationary on level ground during this 2-3 minute process.
14. 14

    HVAC and Thermal Management Calibration
    Navigate to thermal management system module. Execute 'Battery Thermal System Calibration' to reset coolant flow algorithms and temperature control parameters. Then execute 'HVAC System Reset' to clear adaptive climate control learning. Each process takes 2-3 minutes.
15. 15

    Final System Verification
    Perform final complete system scan with diagnostic software. Verify no active fault codes present. Check that all module calibration completion flags show 'successful'. Review BMS data to confirm all cell voltages are reading and within 0.010V of each other. Verify motor position sensors show valid readings. Clear any informational codes and save final scan report.

Reassembly

1. Ensure all high-voltage access panels and floor covers are properly reinstalled
2. Close and secure hood and cargo area
3. Remove HV warning signs from work area
4. Disconnect battery maintainer
5. Store all high-voltage safety equipment properly

Verification

• Power vehicle to Ready mode - verify smooth power-up with no warning messages
• Check instrument cluster for proper SOC display and no warning lights
• Test regenerative braking in both drive and one-pedal mode at low speed - should feel smooth and progressive
• Verify HVAC system operates normally and battery thermal management activates when needed
• Perform test drive of at least 10 miles including various speeds and conditions
• Monitor for smooth power delivery from both motors with no hesitation or roughness
• Verify steering angle sensor is properly calibrated by driving straight and confirming no steering wheel position warnings
• After test drive, perform final diagnostic scan to confirm no new fault codes
• Advise customer that vehicle will relearn driving patterns over next 50-100 miles and performance will optimize during this period
• Document all calibration completion in service records with before/after diagnostic scan files

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