EV Annual Inspection

Comprehensive annual inspection of the 2024 Rivian EDV 500 electric delivery van covering high-voltage system safety checks, battery condition assessment, fluid levels, brake system, tire inspection, and software diagnostics.

Warnings

Tools required

Parts

• Cabin air filter × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt
• Windshield Washer Fluid — 3.5 qt
• EV Battery/Motor Coolant — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been stationary for at least 30 minutes to allow high-voltage system and coolant to cool
3. Connect Rivian diagnostic software and verify communication with vehicle control modules
4. Place vehicle in Service Mode through diagnostic software to disable high-voltage system and prevent unintended movement
5. Verify high-voltage system is de-energized using diagnostic software status indicators
6. Don appropriate personal protective equipment including insulated gloves for high-voltage work
7. Lift vehicle on proper lift points per Rivian service manual specifications and secure with jack stands if needed

Procedure

1. 1

   Perform Diagnostic System Scan
   Using Rivian diagnostic software, perform a complete vehicle system scan. Check for any stored diagnostic trouble codes (DTCs) in all modules including battery management system, motor controllers, charging system, brake system, and body control modules. Document all codes and review service bulletins for any relevant updates or recalls. Check software version and note if updates are available.
2. 2

   Inspect High-Voltage Battery Pack
   Review battery pack status through diagnostic software, checking cell voltage balance, state of health (SOH), state of charge (SOC), and thermal management system operation. Inspect battery pack housing from underneath for physical damage, corrosion, or leakage. Check high-voltage cable connections at battery pack for proper seating, damage to insulation, or corrosion at terminals. Verify battery pack mounting bolts show no signs of looseness or damage.
3. 3

   Inspect High-Voltage Components and Cables
   Visually inspect all high-voltage cables (orange-colored) for damage, abrasion, proper routing, and secure connections. Check both front and rear motor assemblies for coolant leaks, unusual noise history, or physical damage. Inspect onboard charger, DC-DC converter, and power distribution modules for damage or coolant leaks. Verify all high-voltage connector locks are properly seated and safety covers are in place.
4. 4

   Check Battery and Motor Coolant System
   Inspect coolant expansion tank level with system cold - should be between MIN and MAX marks. Check coolant color and condition (should be bright pink/red for EV coolant). Test coolant freeze protection using refractometer (should protect to -40°F). Inspect all visible coolant hoses, connections, and heat exchangers for leaks, damage, or deterioration. Check coolant pump operation through diagnostic software. Top off coolant if needed using only specified EV Battery/Motor Coolant.
5. 5

   Inspect Brake System
   Check brake fluid level in reservoir and verify fluid is clean and clear (not dark or contaminated). Test brake fluid moisture content using brake fluid tester - should be below 3% water content for DOT 4. Inspect all four brake calipers, rotors, and pads. Measure brake pad thickness at all four corners - minimum thickness is 3mm. Check for uneven wear, cracks in rotors, or seized caliper slides. Test electronic parking brake operation through diagnostic software. Check brake lines and hoses for leaks, damage, or corrosion.
6. 6

   Inspect Tires and TPMS
   Check tire pressure at all four corners plus spare if equipped - adjust to specification on door placard (typically 60-65 PSI for EDV 500). Measure tread depth at multiple points on each tire using tread depth gauge - minimum legal depth is 2/32 inch, replace at 4/32 inch. Inspect tires for uneven wear patterns, cuts, bulges, or embedded objects. Verify TPMS sensors are functioning and reporting through diagnostic software. Check tire age from DOT date code - commercial tires should typically be replaced after 6 years regardless of tread depth.
7. 7

   Inspect Steering and Suspension
   Inspect steering system for proper operation - EDV uses electric power steering with no fluid. Check for excessive play in steering wheel or unusual noises. Inspect all suspension components including control arms, ball joints, tie rod ends, and bushings for wear, damage, or torn boots. Check shock absorbers for leaks or damage. Inspect CV axles and boots at all four corners for tears, leaks, or excessive play. Rock wheels to check for bearing play.
8. 8

   Check Drive Unit and Differential Fluids
   Inspect front drive unit for oil leaks at seals and fill plug. If accessible without removing skid plates, check front differential oil level through fill plug - should be at bottom of fill hole (1.5 qt capacity, 75W-90 GL-5). Repeat inspection for rear drive unit (2.0 qt capacity, 75W-90 GL-5). Check for metal contamination on magnetic fill plugs if removed. Inspect drive unit mounting for secure attachment and no damage.
9. 9

   Inspect Underbody and Cargo Area
   Perform complete underbody inspection checking for damage to battery pack protection plates, suspension components, and frame members. Look for signs of impact, corrosion, or loose fasteners. Inspect cargo area floor and walls for damage. Check all underbody covers and aerodynamic panels are secure. Verify tow hooks and recovery points are intact. Inspect exhaust for HVAC system for proper routing and no damage.
10. 10

    Check Lighting and Exterior Systems
    Test operation of all exterior lights including headlights (high and low beam), turn signals, brake lights, cargo area lights, and emergency flashers. Inspect lenses for cracks or moisture intrusion. Check windshield wipers for wear and proper operation. Test windshield washer system and refill reservoir to full (3.5 qt capacity). Inspect mirrors, door handles, and cargo door operation. Check condition of weather stripping and seals.
11. 11

    Inspect Cabin and Safety Systems
    Replace cabin air filter with new OEM filter. Test operation of HVAC system in all modes. Check operation of all interior lights, displays, and controls. Verify proper operation of seat belts at all positions - check for fraying, proper retraction, and secure mounting. Test backup camera and sensors for proper operation. Check fire extinguisher if equipped and verify charge status and inspection date.
12. 12

    Test Charging System
    Inspect charging port door for damage and proper operation. Check charging port contacts for damage, burning, or corrosion. Test AC charging function by plugging in Level 2 charger and verifying vehicle accepts charge and charging indicator illuminates properly. Review charging system performance data through diagnostic software including charge rate capability and any charge faults. If DC fast charging is available, verify DC charge port functionality.
13. 13

    Perform Final Software Checks and Updates
    Check for available software updates for vehicle control systems through Rivian diagnostic portal. If updates are available and authorized, perform software updates following Rivian procedures. Clear any informational codes that were addressed during inspection. Verify all systems show ready status. Generate and save complete vehicle health report. Exit Service Mode and verify vehicle returns to normal operation.

Reassembly

1. Lower vehicle from lift and remove jack stands if used
2. Perform final walk-around inspection to ensure all panels, covers, and inspection points are properly secured
3. Verify no tools or equipment are left in or under vehicle
4. Exit Service Mode through diagnostic software and verify vehicle systems return to normal operation

Verification

• Start vehicle and verify no new warning lights or messages appear on instrument cluster
• Test drive vehicle to verify normal operation of regenerative braking, acceleration, steering, and brake feel
• Verify no unusual noises, vibrations, or handling issues during test drive
• Confirm all identified issues are documented in service report with recommendations for repair or monitoring
• Verify diagnostic software shows no active fault codes and all systems reporting normal status
• Document inspection findings including battery state of health, tire measurements, brake measurements, and fluid conditions in vehicle service records and Rivian service portal

More procedures for this vehicle