Perform a comprehensive state safety inspection on a 2023 Rivian EDV 500 electric delivery van, verifying all safety systems, lighting, brakes, suspension, tires, and electric vehicle-specific components meet regulatory requirements.

Warnings

Tools required

Preparation

1. Verify vehicle registration and documentation match the vehicle being inspected
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks behind rear wheels
4. Ensure vehicle has at least 50% battery charge for complete system testing
5. Power on vehicle to accessory mode to check dashboard warning lights
6. Verify VIN matches registration documents at dashboard and door jamb locations

Procedure

1. 1

   Perform Initial Visual Inspection
   Walk around vehicle and inspect exterior condition. Check for structural damage, body rust or corrosion, broken or missing body panels, and overall vehicle condition. Inspect windshield and all glass for cracks or damage that obstructs driver vision. Verify all required decals and placards are present, including high-voltage warning labels and cargo area placards.
2. 2

   Test All Lighting Systems
   With vehicle powered on, test headlights (low and high beam), turn signals (front and rear, both sides), hazard lights, brake lights, reverse lights, and license plate light. Check all marker lights and clearance lights on cargo body. Verify DRLs (daytime running lights) function. Check for proper headlight aim using headlight aiming equipment - low beams should aim properly without blinding oncoming traffic. All lights must illuminate without flickering or dim output.
3. 3

   Inspect Wipers and Washers
   Test windshield wipers at all speed settings. Verify wiper blades make clean contact without streaking, tearing, or missing sections. Test windshield washer system for proper fluid spray pattern and coverage. Check washer fluid level and top off if necessary. Inspect wiper arms for proper spring tension and secure mounting.
4. 4

   Test Horn and Safety Warning Systems
   Test horn for adequate volume and proper operation. Verify backup alarm/warning system functions when vehicle is placed in reverse (required on commercial vehicles). Check that all dashboard warning lights illuminate during vehicle self-test and extinguish after startup. Verify no active warning lights indicate system failures.
5. 5

   Scan Vehicle Diagnostic System
   Connect OBD-II scan tool to diagnostic port. Scan for active diagnostic trouble codes (DTCs) in all vehicle modules including powertrain, ABS, airbag, and body control systems. Document any codes present. For state inspection, verify no active codes related to safety systems (brakes, steering, airbags, traction control). Check high-voltage battery system status shows no faults or isolation errors.
6. 6

   Inspect Steering System
   With vehicle powered on, turn steering wheel lock-to-lock while stationary to check for excessive play, binding, or unusual noises. Maximum steering wheel free play should not exceed approximately 2 inches. Power on vehicle and verify electric power steering operates smoothly without warning lights. Visually inspect steering column boots and couplings for damage or wear.
7. 7

   Inspect Front Suspension and Undercarriage
   Safely raise vehicle on lift or jack stands at designated lift points. Inspect front suspension components including control arms, ball joints, tie rod ends, and CV axle boots for wear, damage, or excessive play. Check for fluid leaks from shock absorbers. Inspect front subframe and underbody for structural damage or excessive corrosion. Verify all underbody shields and battery pack protective covers are properly secured with no damage.
8. 8

   Inspect Rear Suspension and Drive Components
   Inspect rear suspension components including control arms, shock absorbers, and rear axle mounts for wear or damage. Check rear motor/differential mounts for secure attachment and no fluid leaks. Inspect driveshafts (if AWD configuration) for damage or missing balance weights. Verify exhaust system (if equipped with cabin heater) is secure with no leaks or excessive corrosion.
9. 9

   Inspect Brake System Components
   Inspect brake rotors on all four corners for minimum thickness, scoring, or cracking. Measure rotor thickness with micrometer if available and compare to manufacturer specifications. Visually inspect brake pads through wheel for minimum thickness (should be at least 3mm remaining). Check brake calipers for fluid leaks or damage. Inspect brake lines and hoses for cracks, abrasion, or deterioration. Verify parking brake cables are not frayed or seized.
10. 10

    Test Brake System Performance
    Lower vehicle to ground. With vehicle powered on, pump brake pedal several times and verify firm pedal feel with no excessive travel. Pedal should not sink slowly to floor when held under pressure. Apply parking brake and attempt to move vehicle forward - parking brake should hold vehicle securely. Test brake performance in safe area at low speed - vehicle should stop straight without pulling to either side. Check ABS system activates properly by verifying ABS warning light extinguishes after startup.
11. 11

    Inspect Tires and Wheels
    Inspect all four tires plus spare tire (if equipped) for proper tread depth using tread depth gauge. Minimum legal tread depth is typically 2/32 inch but may vary by state. Check tire sidewalls for cuts, bulges, exposed cords, or weather checking. Verify tire size matches vehicle specifications and all four tires are same size. Check tire pressure on all tires including spare and adjust to door jamb specifications. Inspect wheels for cracks, bends, or damage. Verify all lug nuts are present and wheel covers are secure.
12. 12

    Inspect Interior Safety Equipment
    Check driver seatbelt and all passenger seatbelts for proper operation, fraying, or damage to webbing and buckles. Verify seatbelts retract properly and latch securely. Check driver seat for secure mounting with no excessive movement or broken adjusters. Verify mirrors (interior and both exterior) are present, secure, and provide adequate visibility. Test door latches on all doors to verify they open and close securely.
13. 13

    Verify Emergency Equipment
    Check that required emergency equipment is present and accessible per commercial vehicle requirements: fire extinguisher (properly charged and mounted), warning triangles or flares, first aid kit (if required). Verify cargo area has functional interior lighting and emergency exit access (if applicable to body configuration).
14. 14

    Perform Final Road Test
    Conduct brief road test if permitted by inspection facility. Accelerate smoothly and verify no unusual noises, vibrations, or pulling to one side. Test brakes at moderate speed in safe area. Verify regenerative braking system operates normally. Check steering response and verify vehicle tracks straight. Listen for any abnormal sounds from suspension or drivetrain during acceleration, deceleration, and turning.
15. 15

    Complete Inspection Documentation
    Document all inspection findings on official state inspection form. Record odometer reading, VIN, and inspection date. Note any deficiencies or items requiring attention. If vehicle passes all inspection criteria, affix inspection sticker per state requirements. If vehicle fails any safety items, provide owner with detailed list of required repairs and do not issue passing inspection certificate. Ensure all documentation is properly signed and filed per state regulations.

Reassembly

1. Ensure vehicle is lowered completely and all jack stands removed before returning to customer
2. Remove wheel chocks and disconnect any test equipment
3. Clear any diagnostic codes that were set during testing procedures if appropriate
4. Return driver seat, mirrors, and controls to original positions

Verification

• Verify inspection sticker is properly affixed and all paperwork is complete
• Confirm no warning lights are active on dashboard
• Verify all inspection criteria have been documented on inspection form
• Ensure customer receives copy of inspection results and any required repair documentation
• For failed inspections, provide detailed explanation of deficiencies and repair requirements

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