EV Annual Inspection

Comprehensive annual inspection of the Rivian EDV 500 electric delivery vehicle covering high-voltage system integrity, battery health, drive motors, cooling systems, brake system, and safety-critical components.

Warnings

Tools required

Parts

• Cabin air filter × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant
• DOT 4 Brake Fluid
• 75W-90 GL-5 Gear Oil
• Windshield Washer Fluid

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power off vehicle completely and remove key fob from cabin
4. Allow high-voltage system to cool for minimum 30 minutes if vehicle was recently operated
5. Open hood and locate 12V battery disconnect if emergency isolation is needed
6. Verify inspection scanner is capable of reading Rivian-specific EV diagnostic codes

Procedure

1. 1

   Perform Initial System Scan
   Connect OBD-II scanner to diagnostic port located under driver side dash. Power on vehicle to accessory mode. Run full system scan including high-voltage battery management system, motor controllers, thermal management, brake system, and chassis modules. Document all active and pending fault codes. Check for software update notifications.
2. 2

   Inspect High-Voltage Battery Pack
   Visually inspect battery pack undercarriage for physical damage, signs of impact, fluid leaks, or corrosion. Check battery pack mounting bolts for tightness. Look for swelling or deformation of pack enclosure. Use infrared thermometer to check for unusual temperature variations across pack surface (should be uniform within 10°F). Review battery state of health (SOH) and state of charge (SOC) from scanner data. Verify no thermal management system alerts.
3. 3

   Check High-Voltage Connections
   With vehicle powered off and wearing insulated gloves, visually inspect all visible orange high-voltage cables for damage, chafing, or exposure. Check cable routing and retention clips. Inspect HV connector boots for damage or moisture intrusion. Do not disconnect any HV connectors unless specifically trained. Verify all HV interlock connectors are fully seated and show no signs of corrosion.
4. 4

   Inspect Drive Motors and Inverters
   Visually inspect front and rear drive motor housings for fluid leaks, physical damage, or loose mounting hardware. Check motor cooling system connections. Inspect inverter units mounted near motors for damage or corrosion. Use infrared thermometer to verify no excessive heat retention at motor housings. Review motor controller diagnostic data from scanner for any performance anomalies or temperature warnings.
5. 5

   Check EV Cooling System
   Inspect EV battery and motor coolant reservoir level (located in engine bay). Coolant should be between MIN and MAX marks. Check coolant color and condition - should be bright pink/red with no contamination. Test coolant freeze point protection (should be -40°F). Inspect all visible cooling hoses and connections for leaks, cracks, or swelling. Check electric coolant pump wiring connections. Verify no coolant odor in cabin (indicates heater core leak).
6. 6

   Inspect Brake System
   Check brake fluid level in master cylinder reservoir - should be between MIN and MAX. Test brake fluid moisture content with test strips (should be below 3% for DOT 4). Inspect brake fluid color (should be clear amber, not dark brown). With vehicle raised, inspect brake pads for remaining thickness (minimum 3mm). Check brake rotors for scoring, cracking, or excessive wear. Inspect brake lines and hoses for leaks, damage, or corrosion. Verify parking brake holds vehicle securely on incline.
7. 7

   Inspect Regenerative Brake System
   Using scanner, verify regenerative braking system functionality and no fault codes. Check brake pedal feel simulator operation. Review regen braking performance data and verify normal operation. Test service brake blending by gently applying brakes at low speed - should feel smooth with no pulsation. Check brake-by-wire system components for physical damage or loose connections.
8. 8

   Check Front and Rear Differentials
   With vehicle raised and supported on jack stands, inspect front and rear differential housings for leaks at seals and fill plugs. Check differential fluid level by removing fill plug - fluid should be at bottom of fill hole. Inspect for metal particles on magnetic fill plug. Check CV axle boots for tears or grease leaks. Rotate wheels by hand and listen for unusual bearing noise or grinding from differentials.
9. 9

   Inspect Suspension and Steering
   Inspect front and rear suspension components for damage, leaks (if air suspension equipped), or excessive wear. Check ball joints and tie rod ends for play. Inspect control arm bushings for cracking or deterioration. Check shock absorbers for leaks. Verify electric power steering system has no fault codes. Test steering for smooth operation with no binding or unusual noises. Check wheel bearings for play by grasping tire at 12 and 6 o'clock and attempting to rock.
10. 10

    Inspect Tires and TPMS
    Check tire pressure on all four tires including spare - refer to door placard for correct pressures (typically 60-70 PSI for commercial van). Measure tread depth at multiple points - minimum legal depth 2/32 inch, recommend replacement at 4/32 inch. Inspect tires for uneven wear, cuts, bulges, or sidewall damage. Verify TPMS sensors are communicating properly with no warning lights. Check wheel lug nut torque and condition.
11. 11

    Test 12V Auxiliary Battery
    Locate 12V auxiliary battery in engine bay. Check battery terminals for corrosion and verify tight connections. Measure battery voltage with multimeter - should read 12.4-12.8V when vehicle is off. Perform load test if equipment available - should maintain above 9.6V under load. Verify 12V charging system operates correctly when vehicle is powered on (should read 13.5-14.5V). Check battery hold-down bracket is secure.
12. 12

    Inspect Underbody and Thermal Shields
    With vehicle raised, perform complete underbody inspection. Check battery pack thermal shields and underbody panels for damage, looseness, or missing fasteners. Inspect frame rails and structural components for damage or corrosion. Check exhaust routing if cabin heater equipped. Verify all underbody fasteners and clips are present and secure. Look for evidence of road debris impact or previous damage.
13. 13

    Check Charging System
    Inspect charge port door operation - should open and close smoothly. Check charge port pins for damage, corrosion, or foreign debris. Verify charge port locking mechanism operates correctly. If equipped with onboard charger, inspect for physical damage or coolant leaks. Verify charging system has no fault codes. Test charge port light functionality. Review charging history from vehicle display for any anomalies.
14. 14

    Inspect Safety and Lighting Systems
    Test all exterior lights including headlights, taillights, brake lights, turn signals, and hazard lights. Verify backup lights and cameras function properly. Check wiper blades for wear and washer fluid level. Test horn operation. Verify all seatbelts retract and latch properly. Check fire extinguisher if equipped and verify current inspection date. Test emergency flashers and verify first aid kit is present and current.
15. 15

    Replace Cabin Air Filter and Final Documentation
    Remove and replace cabin air filter located behind glove box or under dash. Install new filter with airflow direction arrow pointing correctly. Clear any fault codes that are not indicative of actual problems. Reset service reminder if applicable. Document all findings, fault codes, battery SOH percentage, tire tread depths, brake pad thicknesses, and fluid conditions in maintenance records. Generate inspection report with recommendations for any needed repairs.

Reassembly

1. Ensure all underbody panels and thermal shields are securely fastened
2. Verify all fluid fill caps are properly tightened
3. Lower vehicle from jack stands and remove wheel chocks
4. Close hood and charge port door
5. Clear inspection scanner from vehicle and remove tools from cabin

Verification

• Power on vehicle and verify no new warning lights or messages on instrument cluster
• Verify all documented fault codes match inspection findings
• Test drive vehicle to confirm normal operation of regenerative braking, acceleration, and handling
• Verify battery SOH reading is within acceptable range for vehicle age and mileage
• Confirm all safety systems including lights, horn, and wipers function properly
• Verify tire pressures are set to specification and TPMS shows no warnings
• Review inspection report with fleet manager and document any recommended follow-up repairs

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