This procedure covers the removal and replacement of a high voltage battery module in a 2023 Rivian EDV 500, requiring complete de-energization of the high voltage system and battery pack disassembly.

Warnings

Tools required

Parts

• High voltage battery module × 1 — Use OEM specification - module number must match pack configuration
• Battery module thermal interface pads × 1 — Use OEM specification
• HV connector seals × 2 — Use OEM specification
• Battery pack access panel seals × 1 — Use OEM specification
• Battery module mounting hardware kit × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 1 qt

Preparation

1. Park vehicle on level surface with adequate ventilation. Do not perform in enclosed spaces without proper air handling.
2. Ensure Class D fire extinguisher rated for lithium-ion batteries is within immediate reach.
3. Verify replacement battery module matches vehicle configuration and software version.
4. Connect Rivian diagnostic software and record all battery fault codes and module data.
5. Verify technician is wearing proper personal protective equipment: high voltage gloves, face shield, and non-conductive footwear.
6. Place warning tags on driver's seat and steering wheel indicating high voltage work in progress.
7. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for systems to power down.
8. Allow battery pack to reach ambient temperature (60-80°F optimal). Do not work on hot battery packs.
9. Photograph all connections and cable routing for reference during reassembly.

Procedure

1. 1

   De-energize high voltage system
   Using Rivian diagnostic software, command the vehicle into Service Mode to open high voltage contactors. Verify Service Mode is active on vehicle display. Wait minimum 15 minutes for high voltage capacitors to discharge. Use high voltage gloves for all subsequent steps involving orange cables or HV components.
   ⚠️Failure to properly de-energize the system before proceeding will result in electrocution hazard.
2. 2

   Access high voltage disconnect
   Remove rear cargo area trim panels to access high voltage service disconnect. Remove the HV service disconnect cover located near the rear of the battery pack. Wearing high voltage gloves, rotate the service disconnect handle counterclockwise to the OFF position and remove completely. Store disconnect in a secure location away from the vehicle.
   ⚠️Service disconnect must be physically removed and kept in technician's possession to prevent accidental re-energization.
3. 3

   Verify zero voltage
   Using high voltage multimeter, verify 0V DC at the HV service disconnect terminals. Test between positive and negative terminals, then each terminal to vehicle ground. Document all readings. Voltage must read less than 5V DC before proceeding. If voltage is present, wait additional 10 minutes and retest.
   ⚠️Never proceed if any voltage is detected. System may have fault preventing capacitor discharge.
4. 4

   Raise and support vehicle
   Lift vehicle using appropriate lift points specified in service manual. Raise to comfortable working height for underfloor access. Ensure vehicle is stable and secure on lift with adequate clearance to lower battery pack.
   ⚠Battery pack adds significant weight low in vehicle. Ensure lift is rated for vehicle weight and properly positioned.
5. 5

   Remove underbody panels
   Remove all underbody aerodynamic panels and protective covers to expose battery pack. Remove fasteners around perimeter of battery pack access area. Label and organize all fasteners by location for reassembly.
6. 6

   Disconnect battery coolant lines
   Place drain pan under battery pack coolant quick-disconnect fittings. Wearing gloves, disconnect coolant supply and return lines from battery pack. Cap all open coolant fittings immediately to prevent contamination. Expect approximately 1 quart of coolant drainage.
   ⚠Battery coolant may be warm and under slight pressure. Relieve pressure slowly.
7. 7

   Disconnect battery management system connectors
   Locate all Battery Management System (BMS) connectors on the battery pack. Photograph each connector orientation. Release connector locks and carefully disconnect all low voltage sensor harnesses, temperature sensors, and communication cables. Secure cables away from work area.
8. 8

   Support battery pack and remove mounting fasteners
   Position battery lift table or hydraulic jack with battery adapter under the center of the battery pack. Raise jack until it just contacts pack (do not lift yet). Remove all battery pack mounting bolts from structural mounting points. There are typically 16-20 mounting points around the perimeter. Keep fasteners organized by location.
   ⚠Battery pack weighs approximately 1,800 lbs. Ensure lifting equipment is rated appropriately and stable.
9. 9

   Lower battery pack
   With assistant monitoring clearances, slowly lower battery pack using lift table. Lower approximately 12-18 inches to gain access to top of pack. Verify all connections are disconnected and no wiring is under tension. Secure pack in lowered position.
10. 10

    Remove battery pack upper cover
    Remove fasteners securing battery pack upper access cover. Carefully lift cover away exposing individual battery modules. Note position of cover seal and any damaged areas requiring replacement. Set cover in clean, safe location.
    ⚠Battery modules are now exposed. Do not place tools or objects on modules that could cause short circuits or damage.
11. 11

    Identify and document target module
    Using diagnostic software fault codes and module location diagram, identify the specific module requiring replacement. Verify module serial number matches diagnostic data. Photograph module position, all connectors, and adjacent modules. Inspect surrounding modules for any signs of damage, swelling, or thermal damage.
    ⚠If adjacent modules show signs of damage, stop and consult engineering. Module failure may indicate larger pack issue.
12. 12

    Disconnect module high voltage bus bars
    Wearing high voltage gloves, identify the positive and negative bus bar connections to the target module. Remove bus bar mounting hardware carefully, noting exact orientation and torque sequence. Lift bus bars away from module terminals and secure with insulating material to prevent contact. Apply identifying tags to each bus bar.
    ⚠️Even with system de-energized, individual modules retain voltage. Never allow bus bars to contact each other or vehicle ground.
13. 13

    Disconnect module sensor and balancing connectors
    Disconnect the module-level voltage sense connector and cell balancing harness from the target module. These are typically smaller multi-pin connectors on the module top or side. Release any cable retention clips. Secure connectors away from work area.
14. 14

    Remove thermal management connections
    Disconnect any direct thermal management connections to the module. This may include coolant channels or thermal interface contact points. Note the condition of thermal interface pads for replacement.
15. 15

    Remove module mounting fasteners
    Remove all fasteners securing the battery module to the pack structure. Battery modules are typically secured with 4-8 bolts depending on size. Keep fasteners in marked container. Note any shims or spacers under module.
16. 16

    Extract battery module
    Using battery module lifting fixture or appropriate straps, carefully lift the defective module straight up and out of the battery pack. Module weighs 60-80 lbs. Keep module level during removal. Place module in designated containment area away from work zone. Do not stack or place objects on removed module.
    ⚠Defective module may have internal damage. Handle as hazardous material and follow proper disposal procedures.
17. 17

    Inspect module cavity and prepare for installation
    Thoroughly inspect the module cavity for any debris, coolant leaks, or damage. Clean all mounting surfaces. Inspect bus bar connection points for corrosion or damage. Replace thermal interface pads on cooling surfaces. Verify new module serial number and specifications match vehicle requirements.
18. 18

    Install new battery module
    Using lifting fixture, carefully lower new module into position in battery pack. Align module with mounting points and thermal management surfaces. Ensure proper orientation per module labeling and markings. Settle module fully into position before releasing lifting fixture.
    ⚠Do not force module into position. Misalignment can damage cells or connections.
19. 19

    Install module mounting fasteners
    Install all module mounting fasteners with any required shims or spacers. Tighten in a cross-pattern sequence to ensure even seating. Since specific torque values are not available in database, follow values stamped on battery pack or provided in module-specific documentation.
    ℹ️Proper torque is critical for thermal management and structural integrity. Consult OEM specifications.
20. 20

    Connect thermal management interfaces
    Reconnect all thermal management connections to the new module. Ensure thermal interface pads are properly positioned and coolant channels (if equipped) are fully seated with seals in good condition.
21. 21

    Connect module sensors and balancing harness
    Reconnect the voltage sense connector and cell balancing harness to the new module. Ensure connectors are fully seated and locked. Verify connector orientation matches photographs from disassembly. Secure any cable retention clips.
22. 22

    Reconnect high voltage bus bars
    Wearing high voltage gloves, remove insulation from bus bars. Clean bus bar and module terminal contact surfaces with electrical contact cleaner. Apply thin coat of dielectric grease to terminals. Position bus bars onto new module terminals in exact orientation documented during removal. Install and torque bus bar mounting hardware per OEM specifications in proper sequence.
    ⚠️Improper bus bar connections can cause arcing, thermal events, or system failure. Verify proper torque and connection integrity.
23. 23

    Reinstall battery pack upper cover
    Inspect cover seal and replace if damaged. Position upper cover onto battery pack, ensuring proper alignment with all mounting points. Install all cover fasteners and tighten in sequence per service manual. Verify cover is fully seated with no gaps.
24. 24

    Raise and secure battery pack
    With assistant monitoring clearances and connections, slowly raise battery pack using lift table back into installed position in vehicle. Align all mounting points. Install all battery pack mounting bolts and tighten per OEM specifications. Remove lift table once pack is fully secured.
    ⚠Verify no wiring or coolant lines are pinched during pack installation.
25. 25

    Reconnect BMS connectors
    Reconnect all Battery Management System connectors, temperature sensors, and communication cables to battery pack. Reference photographs to ensure correct routing and orientation. Verify all connector locks are engaged. Check that no cables are under tension or at risk of chafing.
26. 26

    Reconnect battery coolant lines
    Remove caps from coolant fittings. Inspect quick-disconnect fittings and replace O-rings if worn. Connect coolant supply and return lines to battery pack. Verify connections are fully seated and locked. Wipe away any spilled coolant.
27. 27

    Reinstall underbody panels
    Reinstall all underbody aerodynamic panels and protective covers in reverse order of removal. Ensure all fasteners are installed and properly torqued. Verify no tools or parts remain in underbody area.
28. 28

    Lower vehicle and refill coolant system
    Lower vehicle from lift. Locate battery coolant reservoir. Add EV Battery/Motor Coolant to proper level per service manual procedure. Run coolant system purge procedure using diagnostic software to remove air from battery cooling circuit. Recheck coolant level and top off as needed.
    ℹ️Use only specified EV Battery/Motor Coolant. Incorrect coolant can damage battery cooling system.
29. 29

    Perform module registration
    Connect diagnostic software. Enter new module serial number into vehicle system. Perform Battery Management System registration and configuration procedure. This programs the BMS to recognize the new module and integrates it into pack monitoring and balancing algorithms.
    ⚠Module registration is mandatory. Vehicle will not operate properly without completed registration.
30. 30

    Reinstall HV service disconnect
    Reinstall high voltage service disconnect in reverse order of removal. Rotate handle clockwise to ON position. Install service disconnect cover. Remove warning tags from vehicle interior.
31. 31

    Reconnect 12V battery and exit service mode
    Reconnect 12V auxiliary battery negative terminal. Using diagnostic software, command vehicle out of Service Mode. This will close high voltage contactors and energize the system. Monitor for any fault codes or error messages.

Reassembly

1. Verify all underbody panels are fully secured with no missing fasteners
2. Confirm coolant system is filled to proper level with no leaks visible
3. Ensure all tools and equipment are removed from vehicle and work area
4. Verify all protective covers are installed over high voltage components
5. Double-check that HV service disconnect is fully installed and cover is secured

Verification

• Using diagnostic software, verify new battery module is recognized by BMS and reporting normal voltage and temperature
• Check that no high voltage fault codes are present in vehicle system
• Verify all individual cell voltages are within normal range and balanced (typically within 10-20mV)
• Confirm battery pack state of charge displays correctly and matches expected value
• Perform isolation resistance test to verify no HV system leakage to ground (should exceed 500 ohms/volt)
• Test drive vehicle at low speed in safe area to verify proper operation, monitoring battery temperature and voltage
• Recheck coolant level after test drive and verify no leaks at coolant connections
• Verify battery thermal management system operates correctly during conditioning
• Document all module data, serial numbers, and configuration in service records
• Provide customer with battery service report including new module information and any recommended follow-up

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