This procedure covers the removal, replacement, and reprogramming of the Battery Management System (BMS) control module on the 2024 Rivian EDV 500 dual motor electric delivery van.

Warnings

Tools required

Parts

• Battery Management System control module × 1 — Use OEM specification
• BMS connector seals/gaskets × 1 — Use OEM specification
• High voltage interlock connector × 1 — Use OEM specification
• Thermal interface pad × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify vehicle has been stationary for at least 30 minutes to allow high voltage system to stabilize
3. Ensure battery state of charge is between 30-80% for safe servicing
4. Connect Rivian diagnostic software and document all existing fault codes
5. Create backup of current BMS configuration and calibration data
6. Place high voltage warning signs on vehicle exterior
7. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
8. Don high voltage personal protective equipment (insulated gloves, face shield, long sleeves)
9. Verify all diagnostic equipment is functioning and calibrated

Procedure

1. 1

   Access high voltage service disconnect
   Remove rear cargo area floor panels and insulation to access the high voltage battery pack. Locate the manual service disconnect (MSD) cover on the battery pack. Remove the cover fasteners and lift cover to expose the service disconnect plug. Document the orientation and position before removal.
   ⚠Do not force trim panels. Locate all hidden clips before attempting removal to prevent damage.
2. 2

   Disable high voltage system
   Using insulated gloves, grasp the manual service disconnect handle and pull straight up with firm, steady pressure to remove. The disconnect will have a distinct click when fully disengaged. Store the disconnect in a secure location away from the vehicle. Install lockout device on the disconnect receptacle and attach tagout documentation with your name and date.
   ⚠️Ensure the manual service disconnect is completely removed and locked out. Partial disconnection still allows high voltage to be present in the system.
3. 3

   Verify high voltage isolation
   Wait minimum 10 minutes for high voltage capacitors to discharge. Using a calibrated high voltage multimeter, measure voltage across the HV positive and negative bus bars at the disconnect location. Verify reading is below 5 volts DC. Measure voltage from each HV terminal to vehicle chassis ground. Document all readings. Only proceed if all voltage measurements are safe.
   ⚠️Never skip voltage verification. Capacitors may retain lethal charge even after disconnect removal.
4. 4

   Access BMS module location
   The BMS module is mounted to the underside of the battery pack enclosure, typically on the driver side near the front. From underneath the vehicle on a lift, remove the lower battery pack protective cover by removing perimeter fasteners. Carefully lower the cover and set aside. Locate the BMS module and its associated wiring harnesses.
   ⚠Battery pack cover is aluminum and can be heavy. Use appropriate support when removing to prevent injury or damage.
5. 5

   Disconnect BMS communication harnesses
   Identify all connectors to the BMS module: main CAN bus connectors (typically 2), cell voltage sense harness connector, temperature sensor array connector, and high voltage interlock connector. Release each connector lock by pressing the release tab and gently rocking the connector while pulling straight away from the module. Label each connector with tape for reassembly reference.
   ℹ️Connectors may be stiff from sealant. Do not force or pry with metal tools which may damage pins.
6. 6

   Disconnect high voltage sense leads
   Wearing insulated gloves even though system is de-energized, locate the high voltage positive and negative sense wire connections to the BMS module. These are typically smaller gauge wires with orange insulation and safety covers. Remove the safety covers, then disconnect the sense wire terminals from the BMS module. Cap each terminal with insulating covers.
   ⚠️Although system is de-energized, always treat high voltage components as live. Use insulated tools and gloves.
7. 7

   Remove BMS module mounting
   Remove the BMS module mounting fasteners using appropriate socket or Torx bit. The module is typically secured with 4-6 fasteners and may have thermal interface material between the module and battery pack housing. Once fasteners are removed, carefully separate the module from its mounting surface. If thermal pad is adhered, use gentle twisting motion to break adhesion.
   ⚠BMS module contains sensitive electronics. Handle by edges only and avoid dropping or impact.
8. 8

   Inspect and prepare mounting surface
   With old BMS module removed, inspect the mounting surface on the battery pack for corrosion, damage, or debris. Clean the mounting surface with isopropyl alcohol and lint-free cloth. Inspect all connector pins in the vehicle harnesses for corrosion, damage, or debris. Clean as necessary with electrical contact cleaner.
   ℹ️Mounting surface must be clean and flat to ensure proper thermal transfer from BMS module.
9. 9

   Install thermal interface material
   Remove backing from new thermal interface pad and carefully align it to the BMS module mounting surface on the battery pack. Press firmly to ensure full contact and no air bubbles. Verify thermal pad completely covers the contact area where BMS module will mount.
10. 10

    Install new BMS module
    Remove new BMS module from ESD protective packaging. Verify part number matches vehicle specification and existing module. Carefully position new BMS module onto mounting location, aligning mounting holes and ensuring thermal pad makes full contact. Install mounting fasteners and tighten in star pattern to ensure even pressure distribution. Since torque specifications are not available in database, follow values specified in Rivian service manual for this vehicle.
11. 11

    Reconnect high voltage sense leads
    Remove insulating caps from high voltage sense wire terminals. Reconnect positive and negative sense leads to corresponding terminals on new BMS module. Ensure connections are fully seated and secure. Reinstall safety covers over sense wire connections. Verify orange high voltage identification is visible on all HV wiring.
12. 12

    Reconnect BMS communication harnesses
    Using the labels applied during disassembly, reconnect each communication harness to the new BMS module in correct locations. Start with cell voltage sense harness, then temperature sensor array, CAN bus connectors, and finally high voltage interlock connector. Push each connector until a distinct click is heard and verify the locking tab is fully engaged.
13. 13

    Program and configure new BMS module
    With all electrical connections complete but high voltage still disconnected, reconnect 12V auxiliary battery. Connect diagnostic software to vehicle. Follow Rivian service procedures to program new BMS module with VIN-specific calibration data. Restore backed-up configuration parameters. Perform BMS initialization routine which will establish communication with all battery cell monitoring circuits.
14. 14

    Re-enable high voltage system
    With programming complete and verified, disconnect diagnostic tool. Remove lockout/tagout from manual service disconnect receptacle. Don high voltage protective equipment. Insert manual service disconnect plug, ensuring correct orientation, and push firmly until it clicks and locks into place. Install service disconnect cover and secure with fasteners.
15. 15

    System verification and testing
    Reconnect diagnostic software. Clear any DTCs generated during service. Power on vehicle to READY mode and verify BMS communication is established. Check for any fault codes related to battery system, cell voltage monitoring, or BMS communication. Perform battery system health check using diagnostic software. Verify all cell voltages are being reported and temperatures are within normal range.

Reassembly

1. Reinstall lower battery pack protective cover and secure all fasteners
2. Reinstall rear cargo floor panels and insulation in reverse order of removal
3. Remove all high voltage warning signs from vehicle
4. Verify all tools and equipment have been removed from vehicle and workspace

Verification

• Using Rivian diagnostic software, verify no active or pending DTCs related to battery management system
• Confirm all battery cell voltages are being reported and are within 0.020V of each other
• Verify battery pack temperature sensors are all reading and within expected range
• Perform a charge cycle test: plug in vehicle and confirm BMS properly controls charging to target SOC
• Perform a short test drive and monitor battery system parameters for any abnormalities
• Verify regenerative braking functions properly, indicating BMS is managing power flow correctly
• Generate service report documenting BMS replacement, configuration, and all verification test results
• Update vehicle service records with new BMS module serial number and calibration data

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