High Voltage Service Disconnect

This procedure safely disconnects the high voltage battery system on the 2023 Rivian EDV 500, isolating all high voltage components to allow safe service work on electrical systems.

Warnings

Tools required

Parts

• HV service plug cover seal × 1 — Use OEM specification
• Panel retaining clips (if damaged) × 5 — Use OEM specification

Preparation

1. Verify you have completed high voltage electric vehicle safety training and certification
2. Ensure vehicle is parked on level ground in a dry, well-ventilated area away from flammable materials
3. Verify work area has proper high voltage warning signage posted
4. Place wheel chocks at all four wheels
5. Power off the vehicle completely using the main power button and remove key fob from vehicle interior
6. Wait minimum 5 minutes for all vehicle systems to power down completely
7. Establish lockout/tagout procedures to prevent accidental vehicle activation
8. Put on appropriate PPE: high voltage insulated gloves, safety glasses, and non-conductive footwear
9. Place insulated mat on ground where you will be working
10. Connect Rivian diagnostic software to vehicle OBD-II port
11. Document any existing fault codes in service records

Procedure

1. 1

   Verify vehicle power-down
   Confirm vehicle has been powered off for at least 5 minutes. Attempt to power on vehicle to verify key fob is removed and vehicle will not activate. Check that all interior lights, displays, and indicators are completely off. Verify diagnostic software shows vehicle in sleep mode.
2. 2

   Disconnect 12V auxiliary battery
   Open rear access panel to locate 12V auxiliary battery. Using appropriate socket, disconnect negative terminal first, then positive terminal. Isolate terminals to prevent accidental reconnection. This removes power from control modules and reduces risk of system activation.
3. 3

   Access HV service disconnect location
   The HV service disconnect is located in the center tunnel area beneath the vehicle. Remove protective belly pan panels using T30 Torx driver. Remove approximately 12 fasteners securing forward center underbody panel. Carefully lower panel and set aside. Locate orange high voltage service disconnect cover.
4. 4

   Remove HV disconnect cover
   Verify you are wearing Class 0 insulated gloves rated for minimum 1000V. Remove warning label from HV service disconnect cover. Remove T25 Torx fasteners (typically 4) securing orange protective cover over service disconnect. Carefully remove cover to expose service disconnect plug assembly. Inspect area for any signs of damage, corrosion, or moisture.
5. 5

   Verify high voltage presence
   Using CAT IV rated multimeter with appropriate high voltage probes, verify voltage present at service disconnect contacts before removal. Expected reading should be 0-800V DC depending on battery state. This confirms system status before disconnect. Document voltage reading in service records.
6. 6

   Remove HV service disconnect plug
   Grasp service disconnect plug handle firmly. Rotate locking mechanism counterclockwise approximately 45 degrees until it releases. Pull plug straight out from receptacle using steady, firm pressure. Do not twist or bend plug during removal. Place removed plug in insulated container away from vehicle and metal surfaces.
7. 7

   Wait for capacitor discharge
   After removing service disconnect, wait minimum 10 minutes for high voltage system capacitors to fully discharge. Set timer to ensure full waiting period. Do not touch any high voltage components during this waiting period. This is critical for safety before performing any high voltage service work.
8. 8

   Verify zero voltage state
   After 10 minute discharge period, use CAT IV rated multimeter to verify zero voltage at service disconnect receptacle contacts. Check voltage between both HV positive and negative terminals to ground, and between HV positive and negative terminals to each other. All readings must be below 5V DC. If voltage is still present, wait additional 5 minutes and retest.
9. 9

   Install lockout/tagout device
   Install high voltage lockout device over service disconnect receptacle to prevent accidental reconnection. Attach lockout tag with technician name, date, and reason for disconnect. Store service disconnect plug in secure location away from vehicle. Photograph lockout installation for service records.
10. 10

    Verify isolation using diagnostic software
    Using Rivian diagnostic software, verify HV isolation status. Software should indicate service disconnect is open and high voltage system is isolated. Check for any unexpected fault codes related to HV system integrity. Document all readings and system status in service records.
11. 11

    Install warning indicators
    Place high voltage service disconnect warning tags on driver door, steering wheel, and any other areas specified by facility safety procedures. These tags must remain in place throughout service work to warn other technicians that HV system is disconnected and vehicle cannot be moved under its own power.

Reassembly

1. Ensure all high voltage service work is complete and area is clean and dry before reconnection
2. Remove lockout/tagout device and verify service disconnect plug contacts are clean and undamaged
3. Align service disconnect plug with receptacle and push firmly until fully seated
4. Rotate locking mechanism clockwise 45 degrees until it locks into place
5. Reinstall orange HV service disconnect protective cover with T25 Torx fasteners
6. Reinstall belly pan underbody panels with T30 Torx fasteners, ensuring proper alignment
7. Reconnect 12V auxiliary battery: positive terminal first, then negative terminal
8. Use Rivian diagnostic software to verify HV system integrity and clear disconnect-related fault codes
9. Remove all warning tags and lockout devices from vehicle
10. Power on vehicle and verify all systems function normally before returning to service

Verification

• Using diagnostic software, confirm high voltage system shows proper isolation status (disconnected or reconnected as intended)
• Verify zero voltage at all accessible HV connection points if disconnect procedure was performed
• Check that all warning tags and lockout devices are properly installed if leaving vehicle in disconnected state
• Confirm 12V auxiliary battery is disconnected and isolated
• Document service disconnect status, voltage readings, and timestamp in vehicle service records
• If reconnecting: verify vehicle powers on normally, charge port functions, and ready-to-drive indicator illuminates
• Confirm no new high voltage system fault codes are present after reconnection
• Test drive vehicle to verify all drive systems function normally if reconnection was performed

Related trouble codes on this vehicle

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