Battery Disconnect Service

This procedure safely disconnects the high-voltage battery system on the 2024 Rivian EDV 500, isolating electrical power for service work on electric drivetrain components.

Warnings

Tools required

Parts

• High-voltage interlock connector seal × 1 — Use OEM specification
• Battery service disconnect plug protective cover × 1 — Use OEM specification
• Underbody panel clips (if damaged) × 5 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place safety cones or barriers around work area to prevent accidental contact
3. Using Rivian diagnostic scanner, enable Service Mode and verify system is ready for disconnect
4. Turn off vehicle completely and remove key fob from cabin (minimum 10 feet away)
5. Open all doors to prevent inadvertent locking during service
6. Verify battery state of charge is below 80% if possible for reduced risk
7. Allow vehicle to sit unpowered for 5 minutes before beginning physical disconnect
8. Put on high-voltage insulated gloves and verify no damage or contamination
9. Lay out non-conductive workmat under service area if available

Procedure

1. 1

   Access low-voltage battery and disconnect negative terminal
   Open front hood and locate the 12V low-voltage battery in the front compartment. Using 10mm socket, loosen and remove negative terminal clamp first, then positive terminal. Isolate terminals to prevent reconnection. This de-energizes vehicle control systems.
2. 2

   Remove driver side front wheel well liner access panel
   Using T30 Torx bit, remove the forward section of the driver side front wheel well liner to access the high-voltage service disconnect location. Remove 6 fasteners and carefully pull panel away. Set aside with fasteners.
3. 3

   Locate and identify high-voltage service disconnect
   Identify the bright orange high-voltage service disconnect assembly located behind the wheel well liner. Verify the orange High Voltage warning label is visible. Note the position of the interlock connector (small orange connector) and main disconnect lever.
4. 4

   Disconnect high-voltage interlock connector
   While wearing high-voltage gloves, press the release tab on the small orange interlock connector and carefully pull straight out. This signals the battery management system that service is beginning. Store connector in a safe location away from the service area.
5. 5

   Remove high-voltage service disconnect cover
   Using T40 Torx bit, remove the three fasteners securing the orange service disconnect cover. Carefully lift cover away to expose the manual disconnect lever assembly. Inspect for any signs of arcing, damage, or contamination.
6. 6

   Operate manual service disconnect lever
   Using the Rivian service disconnect tool (or appropriate insulated tool), rotate the manual disconnect lever 90 degrees counterclockwise until it stops. You should feel positive detent indicating full disconnect position. The lever should now be perpendicular to its original position.
7. 7

   Remove service disconnect assembly
   With disconnect lever in OFF position, grasp the orange disconnect assembly handle and pull straight out with steady force. The assembly will slide out approximately 6-8 inches. Store the disconnect assembly in a secure location where it cannot be accidentally reinstalled.
8. 8

   Install lockout/tagout device
   Install appropriate lockout device in the service disconnect cavity to prevent accidental reconnection. Attach service tag indicating the date, technician name, and reason for disconnect. Take a photo of the lockout for service records.
9. 9

   Wait for capacitor discharge period
   Wait minimum 5 minutes (recommended 10 minutes) with vehicle completely disconnected to allow high-voltage capacitors throughout the system to fully discharge. Do not touch any high-voltage components during this waiting period.
10. 10

    Verify zero voltage at high-voltage terminals
    Using high-voltage capable multimeter with insulated test leads, verify voltage between positive and negative high-voltage terminals at the disconnect location reads 0V DC. Also check each terminal to vehicle ground. All readings must be 0V before proceeding with any service work.
11. 11

    Access underbody battery disconnect (if required)
    If service requires additional isolation, raise vehicle on lift to access underbody. Remove the battery pack access panel located at mid-chassis using T30 Torx bit (8 fasteners). Locate secondary service disconnect plug with orange collar.
12. 12

    Disconnect underbody service plug
    While wearing high-voltage gloves, rotate the orange locking collar on the underbody service disconnect counterclockwise, then pull plug assembly straight down. This provides additional isolation of battery pack internal connections. Store plug in safe location.
13. 13

    Document disconnect status
    Using Rivian diagnostic scanner, record the disconnect event in vehicle service history. Document battery state of charge, voltage readings taken, and time of disconnect. Photograph all disconnect points showing their disconnected state.

Reassembly

1. When service is complete, reverse disconnect procedure exactly
2. Before reconnecting, inspect all high-voltage connectors for damage, contamination, or corrosion
3. Install underbody service plug first (if removed), ensuring positive locking engagement and proper seal
4. Install primary service disconnect assembly with alignment marks properly oriented
5. Rotate disconnect lever clockwise to ON position until positive detent is felt
6. Reinstall all protective covers and verify proper sealing
7. Reconnect high-voltage interlock connector last, ensuring positive click engagement
8. Reinstall wheel well liner access panel with all original fasteners
9. Reconnect 12V battery terminals: positive first, then negative
10. Using Rivian diagnostic scanner, exit Service Mode and perform system initialization
11. Verify no high-voltage fault codes stored in vehicle systems
12. Perform ADAS recalibration procedure as required per service manual
13. Test vehicle ready status and verify all systems operational before delivery

Verification

• Confirm all high-voltage disconnects have been properly reinstalled with positive engagement
• Verify high-voltage interlock circuit shows normal status on diagnostic scanner
• Check that battery management system shows normal voltage and no isolation faults
• Confirm vehicle enters READY mode without high-voltage system warnings
• Verify all auxiliary systems (climate control, power steering, brake boost) function normally
• Test drive vehicle to verify normal propulsion operation and regenerative braking function
• Scan for any stored fault codes and verify no high-voltage related codes present
• Document completion of service disconnect/reconnect procedure in vehicle service records

Related trouble codes on this vehicle

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