This procedure covers the removal and replacement of the DC-DC converter on a 2024 Rivian EDV 500 electric delivery van, which converts high-voltage battery power to 12V for auxiliary systems.

Warnings

Tools required

Parts

• DC-DC converter assembly × 1 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification
• Low-voltage connector seal × 1 — Use OEM specification
• Thermal interface pad × 1 — Use OEM specification
• Mounting hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been powered off for at least 30 minutes to allow high-voltage components to cool
3. Verify Rivian diagnostic software is updated and functional
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
5. Remove front cargo area floor panels and stowage compartments to access front trunk area
6. Document all connector orientations and cable routing with photos before disassembly

Procedure

1. 1

   Access high-voltage service disconnect
   Remove the front trunk liner panels to expose the high-voltage battery service disconnect located on the driver side of the front compartment. Remove the orange service disconnect cover by releasing the two retention clips.
2. 2

   Disable high-voltage system
   Pull the high-voltage service disconnect handle straight out until it locks in the open position. Install the provided lockout tag. Verify the high-voltage system indicator light on the dash (if visible) is extinguished. Wait minimum 15 minutes for capacitor discharge.
   ⚠️Do not proceed until full 15-minute waiting period has elapsed. Capacitors retain lethal voltage.
3. 3

   Verify zero voltage
   Don high-voltage insulated gloves. Using a calibrated high-voltage multimeter, measure voltage between high-voltage positive and negative busbars at the service disconnect location. Verify reading is below 5V DC. If voltage is present, wait additional 10 minutes and recheck.
4. 4

   Remove DC-DC converter cover and ducting
   Locate the DC-DC converter assembly mounted on the passenger side firewall in the front trunk area. Remove the protective cover by releasing four quarter-turn fasteners. Disconnect the cooling air duct from the converter heat sink by releasing spring clips on both sides.
5. 5

   Disconnect low-voltage output connector
   Press the release tab on the low-voltage output connector (black 12V cable bundle) and pull straight out from the DC-DC converter. Secure the cable away from the work area. Inspect connector pins for damage or corrosion.
6. 6

   Disconnect high-voltage input connectors
   While wearing high-voltage gloves, unlock the orange high-voltage input connector by sliding the gray locking collar toward the cable. Pull the connector straight out from the DC-DC converter. Repeat for the second high-voltage connector. Cap both connectors with provided protective covers.
   ⚠High-voltage connectors require straight pull motion only. Do not twist or rock connectors during removal.
7. 7

   Disconnect coolant lines
   Position drain pan beneath DC-DC converter. Using quick-disconnect tool, release the coolant inlet and outlet lines from the converter. Expect approximately 0.5 quarts of EV coolant to drain. Plug lines immediately with provided caps to prevent contamination.
8. 8

   Remove mounting fasteners
   Support the DC-DC converter weight with one hand or support fixture. Remove the four mounting bolts securing the converter to the firewall bracket. Note the location of any ground straps or additional brackets attached to the mounting points.
9. 9

   Remove DC-DC converter assembly
   Carefully maneuver the DC-DC converter away from the mounting bracket, ensuring no cables or hoses are still attached. The converter weighs approximately 25 pounds. Place on clean work surface for inspection. Check mounting bracket and heat sink interface surface for damage.
10. 10

    Prepare replacement converter
    Remove new DC-DC converter from packaging. Verify part number matches OEM specification. Inspect all connector interfaces for shipping damage. Apply new thermal interface pad to the mounting surface, ensuring complete coverage and proper alignment with mounting holes. Remove protective film from adhesive side.
11. 11

    Install replacement converter
    Position new DC-DC converter onto mounting bracket, aligning thermal interface pad with heat sink surface. Install four mounting bolts finger-tight first, then torque in cross pattern to ensure even pressure on thermal interface. Reconnect any ground straps to designated mounting points.
12. 12

    Reconnect coolant lines
    Remove caps from coolant lines. Inspect quick-connect fittings for debris. Push coolant inlet and outlet lines firmly into converter ports until they click and lock. Tug gently to verify engagement. Wipe any spilled coolant from surrounding components.
13. 13

    Reconnect high-voltage connectors
    While wearing high-voltage gloves, remove protective caps from high-voltage connectors. Inspect connector seals and replace if damaged. Align connector keys and push firmly into DC-DC converter ports until fully seated. Slide gray locking collars toward the converter until they click into locked position. Verify locks are engaged.
14. 14

    Reconnect low-voltage connector and ducting
    Align low-voltage output connector and push firmly into DC-DC converter until retention tab clicks. Reinstall cooling air duct to heat sink, ensuring spring clips engage properly on both sides. Reinstall protective cover and secure with four quarter-turn fasteners.
15. 15

    Commission replacement converter
    Connect Rivian diagnostic software to vehicle. Follow on-screen prompts to register new DC-DC converter serial number to vehicle. Software will perform initial configuration and verify communication with vehicle systems. Do not reconnect high-voltage service disconnect until commissioning is complete.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Remove lockout tag and reinstall high-voltage service disconnect, pushing firmly until it locks
3. Reinstall high-voltage disconnect cover with retention clips
4. Reinstall front trunk liner panels and stowage compartments
5. Verify all tools and parts have been removed from vehicle
6. Check coolant level in reservoir and top off with EV Battery/Motor Coolant if needed

Verification

• Power on vehicle and verify DC-DC converter status shows normal in Rivian diagnostic software
• Verify 12V auxiliary battery is charging (should show 13.5-14.5V with vehicle in ready mode)
• Check for coolant leaks around DC-DC converter connections
• Monitor DC-DC converter temperature during 10-minute idle period to ensure cooling system is functioning
• Perform test drive and verify all 12V systems operate normally (lights, wipers, HVAC, infotainment)
• Re-check all high-voltage connector locks and fasteners are secure
• Clear any diagnostic trouble codes and verify none return after test cycle

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