This procedure covers the removal and replacement of a high voltage battery module in a 2024 Rivian EDV 500 electric delivery van, requiring complete HV system de-energization and coolant system drainage.

Warnings

Tools required

Parts

• High voltage battery module × 1 — Use OEM specification - module serial number specific
• HV battery module thermal pad/gasket × 1 — Use OEM specification
• Battery coolant quick-disconnect seals × 2 — Use OEM specification
• HV interlock connector seal × 1 — Use OEM specification
• Battery module mounting hardware kit × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Verify battery state of charge is between 20-40% using vehicle display. Do not perform this work with battery above 80% or below 10% charge.
2. Park vehicle on level surface in well-ventilated area away from ignition sources. Set parking brake and chock rear wheels.
3. Allow high voltage system to cool for minimum 2 hours if vehicle was recently operated.
4. Disconnect 12V auxiliary battery negative terminal and wait 10 minutes for vehicle systems to power down completely.
5. Connect Rivian diagnostic software and document all fault codes and battery module serial numbers. Save battery health report for reference.
6. Using diagnostic software, command the vehicle into 'Service Mode' and enable 'HV Battery Service Lockout'.
7. Place high voltage safety warning tags on steering wheel and charge port.
8. Raise vehicle on lift to comfortable working height, ensuring stability and proper support on manufacturer-designated lift points.
9. Remove rear cargo area floor panels and access covers to expose battery pack access points.
10. Place coolant drain pan beneath battery pack coolant drain location.

Procedure

1. 1

   De-energize high voltage system
   Open the HV service disconnect panel located in the rear cargo area. Wearing insulated high voltage gloves, rotate the service disconnect lever counterclockwise 90 degrees to the OFF position. Remove the service disconnect handle completely and store it in a secure location away from the work area. Install lockout device on service disconnect panel and attach warning tag.
   ⚠️Ensure insulated gloves are rated for minimum 1000V and are free from damage, tears, or contamination before touching any HV components.
2. 2

   Verify zero voltage state
   Wait minimum 15 minutes after HV disconnect. Using high voltage-rated multimeter, verify zero voltage (less than 5V DC) at the HV busbar test points located adjacent to the service disconnect. Test between positive and negative busbars, positive to chassis ground, and negative to chassis ground. Document all voltage readings. Do not proceed if any voltage above 5V is detected.
   ⚠️If voltage is present after 15 minutes, do not proceed. Contact Rivian technical support as this indicates a capacitor discharge failure or other electrical system fault.
3. 3

   Drain battery coolant system
   Locate the battery coolant drain valve on the underside of the battery pack. Attach drain hose to valve and route to drain pan. Slowly open drain valve and allow coolant to drain completely (approximately 10 quarts). Once drained, close valve. Locate and disconnect the battery pack coolant supply and return quick-disconnect fittings using appropriate disconnect tool. Cap or plug open fittings to prevent contamination.
   ⚠Battery coolant may still be warm. Wear appropriate gloves and eye protection. Coolant is toxic and must be captured for proper disposal or recycling.
4. 4

   Disconnect HV interlock circuit
   Locate the HV interlock connector on the battery pack perimeter. This orange connector includes a detection circuit that monitors HV enclosure integrity. Depress connector locking tab and carefully disconnect. Inspect interlock connector pins for corrosion or damage. Store connector in a clean, dry location. Remove and discard interlock connector seal.
5. 5

   Remove battery pack lower protective covers
   From underneath the vehicle, remove all battery pack lower protective covers and skid plates. There are typically 24-32 fasteners (10mm hex) securing these covers. Work systematically from rear to front, keeping fasteners organized by location. Remove acoustic insulation panels if equipped. Inspect covers for damage during removal.
6. 6

   Disconnect battery module electrical connectors
   Locate the specific battery module to be replaced using the module identification labels and diagnostic software location data. Each module has two main HV busbar connections and one temperature sensor connector. Using insulated tools, remove the HV busbar retention bolts (typically 13mm). Carefully lift busbars away from module terminals and secure away from work area with insulated tape. Disconnect temperature sensor connector.
   ⚠️Although system is de-energized, treat all HV connections as live. Do not allow busbars or tools to create a short circuit path across module terminals or to chassis ground.
7. 7

   Disconnect module coolant lines
   Each battery module has dedicated coolant inlet and outlet connections. Using appropriate disconnect tool, release the quick-disconnect fittings at the module. Be prepared for residual coolant spillage (approximately 1-2 cups). Cap or plug all open coolant connections immediately to prevent contamination. Inspect O-rings and seals for damage.
8. 8

   Remove battery module mounting hardware
   Battery modules are secured to the pack frame with multiple mounting brackets and fasteners. Identify all mounting points for the specific module being replaced (typically 6-8 locations with 13mm or 15mm bolts). Remove mounting bolts in a cross-pattern to prevent binding. Keep all mounting hardware organized and inspect threads for damage.
9. 9

   Extract battery module from pack
   Position battery module lifting fixture or transmission jack beneath the module. Carefully raise lifting device until it makes secure contact with module lifting points. Verify module is properly supported and balanced on lifting device. Slowly lower module while guiding it away from adjacent modules and pack structure. Watch for any interference with wiring, coolant lines, or structural components. Once clear of pack, lower module to ground and transport to designated safe storage area using proper lifting techniques.
   ⚠️Battery modules weigh 150-200 lbs and must be handled with extreme care. Never work beneath an unsupported module. Use minimum two technicians to guide module during extraction.
   ⚠Do not drop, impact, or allow module to tip during removal. Physical damage can cause internal cell damage leading to thermal runaway.
10. 10

    Inspect battery module compartment
    With module removed, thoroughly inspect the battery pack compartment for any signs of coolant leakage, thermal damage, corrosion, or debris. Check adjacent modules for any signs of swelling or thermal damage. Inspect all coolant lines, electrical connections, and structural mounting points. Clean compartment with compressed air and lint-free cloths. Verify thermal interface pad condition on pack floor where module sits.
11. 11

    Prepare and install replacement battery module
    Unpack new battery module and verify serial number matches work order and Rivian authorization documentation. Inspect new module for any shipping damage. Install new thermal interface pad/gasket on module mounting surface per manufacturer specifications. Position new module on lifting fixture and verify it is properly balanced and secured. Carefully raise module into battery pack compartment, aligning with mounting points and ensuring no interference with coolant lines or electrical connections. Guide module into final position.
    ⚠️New battery modules may have partial charge. Maintain all HV safety precautions. Never allow tools or conductive materials to contact module terminals.
12. 12

    Install module mounting hardware
    Install all battery module mounting brackets and fasteners. Thread all bolts by hand first to ensure proper alignment. Torque mounting bolts in a cross-pattern sequence to prevent module distortion. Since no specific torque values are provided in database, follow manufacturer torque specifications exactly as provided with replacement module or in factory service information. Verify module is properly seated and secure with no gaps or misalignment.
13. 13

    Reconnect module coolant connections
    Install new coolant quick-disconnect seals on module coolant fittings. Clean mating surfaces and inspect for any debris. Connect coolant supply and return lines to module, ensuring quick-disconnects fully engage with audible click. Gently pull on each connection to verify it is secure. Route coolant lines to ensure no interference with other components.
14. 14

    Reconnect module electrical connections
    Connect temperature sensor connector to new module, ensuring full engagement and locking tab engagement. Using insulated tools, carefully position HV busbars onto module terminals, ensuring proper alignment and full contact. Install busbar retention bolts and torque per manufacturer specifications using calibrated torque wrench. Verify all electrical connections are clean, tight, and properly positioned. Double-check that no tools or foreign objects remain in the battery pack.
    ⚠️Ensure busbars are positioned correctly with no possibility of short circuit to adjacent components or chassis ground. Improper connection can cause arc flash when system is re-energized.
15. 15

    Reconnect HV interlock circuit
    Install new HV interlock connector seal. Clean interlock connector and inspect pins for any damage or corrosion. Carefully reconnect HV interlock connector, ensuring full engagement and locking tab secure. Verify connector is properly seated and seal is in place. This circuit must be complete before HV system can be energized.
16. 16

    Refill battery coolant system
    Connect coolant vacuum fill system to battery pack fill port. Perform vacuum fill procedure per equipment manufacturer instructions to ensure complete fill and proper air purging. Typically this involves pulling vacuum on system, then drawing fresh EV Battery/Motor Coolant into system under vacuum. Fill system to proper level (approximately 10 quarts total). Reconnect main coolant supply and return quick-disconnects at battery pack. Close coolant drain valve securely.
    ⚠Use only specified EV Battery/Motor Coolant. Do not use automotive antifreeze or mix coolant types. Improper coolant can cause battery thermal management failure.
17. 17

    Reinstall protective covers and panels
    Reinstall acoustic insulation panels if equipped. Install battery pack lower protective covers and skid plates, torquing all fasteners per manufacturer specifications. Verify all covers are properly aligned and secure. Inside vehicle, reinstall cargo area floor panels and access covers. Verify all interior panels are properly secured and no tools or parts remain in vehicle.
18. 18

    Commission new battery module
    Connect Rivian diagnostic software. Follow the Battery Module Commissioning procedure in the diagnostic software. This process registers the new module serial number to the vehicle VIN, performs initial voltage balancing, and configures battery management system parameters. This procedure typically takes 30-60 minutes and must not be interrupted. Monitor software for any errors or faults during commissioning.
    ⚠Battery module commissioning is critical and must be completed successfully. Failure to properly commission will result in battery system faults, reduced performance, and potential safety issues.
19. 19

    Re-energize high voltage system
    Remove lockout device from HV service disconnect panel. Wearing insulated HV gloves, reinstall service disconnect handle and rotate clockwise 90 degrees to ON position. Close service disconnect panel. Using diagnostic software, disable 'HV Battery Service Lockout' and exit Service Mode. Reconnect 12V auxiliary battery negative terminal. Remove all warning tags from vehicle.
    ⚠️Once HV system is re-energized, all HV components are live at lethal voltage levels. Verify all covers and panels are installed before energizing system.

Reassembly

1. Verify all battery pack protective covers and skid plates are securely installed with all fasteners torqued to specification
2. Confirm all interior panels and cargo area floor covers are properly reinstalled
3. Ensure no tools, parts, or materials remain in or under the vehicle
4. Verify all HV safety lockout devices and warning tags have been removed from vehicle
5. Double-check that service disconnect is in ON position and panel is closed

Verification

• Using diagnostic software, verify battery module commissioning completed successfully with no stored fault codes
• Confirm new battery module appears in vehicle system with correct serial number and all cells reporting voltage within specification (typically 3.0-4.2V per cell)
• Verify battery pack coolant level is correct and system shows no leaks. Check all coolant connections for seepage
• Perform battery thermal management system test using diagnostic software. Verify coolant circulates through new module and module temperature sensors report correctly
• Check battery pack isolation resistance using diagnostic software. Must show greater than 500 ohms/volt (typically >200k ohms) indicating no HV to chassis ground leakage
• Perform vehicle ready test. Vehicle should enter READY mode with no warning lights or battery system alerts
• Conduct test drive to verify normal operation. Monitor battery temperature, voltage, and state of charge during acceleration, regenerative braking, and sustained driving
• After test drive, inspect all work areas for coolant leaks, unusual odors, or any signs of thermal issues
• Using diagnostic software, capture final fault code scan and battery health report. Compare to pre-repair documentation
• Verify vehicle charge port functions correctly and vehicle accepts charge without errors
• Document all work performed including module serial numbers, torque values applied, and final verification results for vehicle service records

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