This procedure covers the removal and replacement of the Power Electronics Module (PEM) on a 2024 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• Power Electronics Module × 1 — Use OEM specification
• PEM mounting gasket/seal × 1 — Use OEM specification
• High voltage connector seals × 4 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for minimum 30 minutes to allow high voltage system to cool
3. Confirm high voltage battery state of charge is below 30% if possible for safety
4. Connect Rivian diagnostic scanner and document any existing fault codes
5. Place high voltage warning signs on vehicle exterior and in cab
6. Ensure fire extinguisher rated for electrical fires is accessible
7. Review vehicle-specific service information for PEM location and high voltage safety procedures

Procedure

1. 1

   Disconnect 12V battery
   Open hood and disconnect negative terminal of 12V battery. Wait 2 minutes for all vehicle modules to power down completely. Isolate negative cable to prevent accidental reconnection.
2. 2

   Disable high voltage system
   Don high voltage insulated gloves. Access high voltage disconnect located in rear cargo area under service panel. Rotate high voltage service disconnect to OFF position and remove disconnect plug. Store disconnect plug in secure location away from vehicle. Place lockout tag on service disconnect panel.
3. 3

   Verify system de-energization
   Wait minimum 15 minutes for high voltage capacitors to discharge. Using high voltage capable multimeter, verify voltage at PEM high voltage terminals reads 0V DC. Test between positive and negative terminals, and from each terminal to chassis ground. Document voltage readings.
4. 4

   Drain coolant system
   Place drain pan under vehicle beneath PEM location. Locate coolant drain valve on underbody coolant line near PEM. Open drain valve and allow EV coolant to drain completely into pan. Capture and measure drained coolant quantity for refill reference. Close drain valve when empty.
5. 5

   Remove underbody panels
   Remove underbody protective panels and shields to access PEM from below. Remove fasteners securing aerodynamic panels around PEM mounting area. Set panels aside in organized manner. Note locations of any differing fastener types for proper reinstallation.
6. 6

   Disconnect coolant lines
   Locate coolant inlet and outlet connections on PEM. Using hose clamp pliers, release spring clamps or loosen screw clamps on coolant hoses. Carefully disconnect coolant hoses from PEM inlet and outlet ports. Cap or plug open ports immediately to prevent contamination. Be prepared for residual coolant spillage.
7. 7

   Disconnect low voltage connectors
   Locate low voltage control connectors on PEM (typically 2-3 multi-pin connectors). Release connector locking tabs and carefully disconnect each low voltage harness connector. Note orientation and position of each connector. Secure disconnected connectors away from work area.
8. 8

   Disconnect high voltage cables
   Wearing high voltage gloves, identify high voltage cables connecting to PEM (typically orange cables from battery pack and motor drive units). Remove high voltage connector locking bolts or release locking mechanisms. Carefully disconnect high voltage connectors from PEM terminals. Inspect connector seals for damage. Secure high voltage cables away from PEM using proper support to prevent stress on connections.
9. 9

   Support PEM weight
   Position cable hoist or support fixture beneath PEM. Attach lifting straps or cables to PEM lifting points or mounting bracket locations. Take up slack in hoist to support PEM weight but do not lift yet. Verify secure attachment and balanced support before proceeding.
10. 10

    Remove PEM mounting fasteners
    Locate PEM mounting bolts securing module to vehicle structure (typically 6-8 mounting points). Remove mounting bolts in sequence working from outer bolts toward center. Keep bolts organized and note any locations with specific bolt lengths or types. Support PEM with hoist as final bolts are removed.
11. 11

    Remove PEM from vehicle
    With hoist supporting full weight of PEM and all fasteners removed, carefully lower PEM from mounting location. Guide module clear of any remaining wiring, cooling lines, or structural components. Lower PEM completely and transfer to clean workbench. Inspect mounting location for any damage or debris.
12. 12

    Install new PEM
    Inspect new PEM for any shipping damage. Install new mounting gasket or seal onto PEM or vehicle mounting surface per service manual specification. Using hoist, position new PEM into mounting location. Align PEM with mounting holes while guiding around any structural components. Ensure no wiring or hoses are pinched during installation.
13. 13

    Install mounting fasteners
    Install PEM mounting bolts hand-tight in sequence starting from center mounting points working outward. Verify PEM is properly seated against mounting surface. Since specific torque values are not provided in database, tighten mounting bolts following pattern specified in Rivian service information, working in multiple stages to ensure even clamping.
14. 14

    Reconnect high voltage cables
    Install new high voltage connector seals on PEM terminals if required. Wearing high voltage gloves, carefully connect high voltage cables to PEM terminals ensuring proper polarity and alignment. Install and tighten high voltage connector locking bolts or engage locking mechanisms per Rivian specifications. Verify connections are fully seated and secure.
15. 15

    Reconnect low voltage and coolant connections
    Reconnect low voltage control harness connectors to PEM ensuring proper seating and connector lock engagement. Connect coolant hoses to PEM inlet and outlet ports. Install new hose clamps and position properly on hose barbs. Tighten clamps securely. Double-check all connections are fully seated.

Reassembly

1. Reinstall underbody protective panels and aerodynamic shields in reverse order of removal
2. Verify all fasteners are installed and properly tightened
3. Refill coolant system with fresh EV Battery/Motor Coolant to specified capacity (10 quarts total system)
4. Bleed air from coolant system per Rivian bleeding procedure using diagnostic tool if required
5. Reinstall high voltage service disconnect plug and rotate to ON position
6. Reconnect 12V battery negative terminal
7. Remove high voltage warning signs from vehicle

Verification

• Connect Rivian diagnostic scanner and clear any stored fault codes from PEM replacement procedure
• Perform PEM configuration and calibration procedures using diagnostic tool as specified by Rivian
• Power on vehicle and verify PEM initialization completes without fault codes
• Check for coolant leaks around PEM connections with vehicle powered on and coolant system pressurized
• Verify high voltage system shows proper voltage readings on diagnostic scanner
• Perform test drive and verify normal vehicle operation including acceleration, regenerative braking, and power delivery
• Verify no warning lights or fault codes present after test drive
• Inspect all connections and mounting points for any signs of looseness or leakage
• Document PEM serial number and installation date in vehicle service records

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