High Voltage Service Disconnect

This procedure safely disconnects the high voltage battery system on the 2024 Rivian EDV 500, isolating all high voltage circuits to allow safe service work on electrical components.

Warnings

Tools required

Parts

• Service disconnect lock-out device × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in a well-ventilated area away from flammable materials
2. Apply parking brake and verify gear selector is in Park
3. Power off the vehicle completely using the infotainment power button and verify all systems are shut down
4. Ensure all doors, windows, frunk, and tailgate are accessible and can be manually opened if needed
5. Place wheel chocks at all four wheels
6. Verify fire extinguisher is within reach and ready for use
7. Don high voltage safety equipment: insulated gloves and face shield
8. Establish lock-out/tag-out procedures if working in a shop environment
9. Notify all personnel in the area that high voltage work is being performed
10. Connect Rivian diagnostic tool and verify no active high voltage system faults are present

Procedure

1. 1

   Access the HV service disconnect compartment
   Open the frunk. Locate the high voltage service disconnect access panel on the driver side of the frunk compartment near the front bulkhead. The panel will have high voltage warning labels (orange lightning bolt). Use panel removal tools to carefully remove the access cover by releasing the retaining clips. Store the panel in a safe location.
2. 2

   Identify high voltage components
   With the access panel removed, identify the high voltage service disconnect assembly. This is a bright orange component with a T-handle or lever mechanism. Identify all orange high voltage cables in the area. Verify the area is dry and free from any coolant or fluid leaks. If any leaks are present, stop and address before proceeding.
3. 3

   Verify vehicle is powered down
   Using the Rivian diagnostic tool, verify the vehicle high voltage system shows as 'Sleep' or 'Off' state. Attempt to power on the vehicle one final time, then power it completely off. Wait 60 seconds to ensure all vehicle systems have entered sleep mode. Verify the instrument cluster is completely dark and no charging indicators are illuminated.
4. 4

   Remove HV service disconnect assembly
   Wearing high voltage insulated gloves, grasp the service disconnect handle firmly. Rotate the handle counterclockwise approximately 90 degrees until it stops or releases (direction may be indicated by arrows on the component). Pull the service disconnect straight out with steady force. The assembly will extract approximately 6-8 inches. Some resistance is normal. Once removed, inspect the disconnect contacts for any signs of arcing, burning, or damage.
   ⚠️The disconnect may have residual voltage. Never touch the contact pins or internal components with bare hands or uninsulated tools.
5. 5

   Secure the service disconnect
   Install the service disconnect lock-out device onto the removed disconnect assembly according to manufacturer instructions. This prevents accidental reinstallation. Place the locked-out disconnect in a secure location away from the vehicle and in a visible area. Attach a lock-out/tag-out tag with your name, date, and reason for disconnect. Never leave the disconnect unattended or accessible to unauthorized personnel.
6. 6

   Install HV system safety barrier
   Insert the supplied orange safety barrier plug or blank into the service disconnect receptacle on the vehicle. This plug prevents moisture ingress and clearly indicates the system is disabled. Ensure it seats fully and locks into place. The barrier should be bright orange and clearly visible.
7. 7

   Wait for capacitor discharge period
   Begin timing a mandatory 10-minute waiting period. Do not touch any high voltage components during this time. This allows high voltage capacitors within the drive units, inverters, and battery management system to safely discharge below hazardous levels. Set a timer and do not proceed until the full 10 minutes has elapsed. Use this time to organize tools and review subsequent work procedures.
8. 8

   Verify zero voltage state
   After the 10-minute discharge period, wearing high voltage insulated gloves, use your 1000V-rated digital multimeter set to DC voltage. Carefully measure voltage between the high voltage bus bars visible in the service disconnect receptacle. Place the black probe on the negative (marked -) terminal and red probe on positive (marked +). Voltage reading must be less than 10 volts DC. If voltage is higher than 10V DC, wait an additional 10 minutes and retest. Do not proceed until voltage is confirmed below 10V DC.
   ⚠️If voltage does not drop below 10V DC after 20 minutes total wait time, do not proceed. A high voltage system fault is present. Contact Rivian service.
9. 9

   Place additional lock-out devices
   If the vehicle is equipped with a 12V battery disconnect or additional safety disconnects, engage those now. Place steering wheel lock-out cover if available. Place 'HIGH VOLTAGE WORK IN PROGRESS' warning signs on the windshield and near the work area. Ensure all personnel are aware the vehicle is disabled.
10. 10

    Document system state
    Using the Rivian diagnostic tool, capture and save a system status report showing the high voltage disconnect state. Take photographs of the removed service disconnect, the installed safety barrier, and your lock-out/tag-out tags with visible date/time. Document any fault codes present. This documentation protects you and provides a record of proper procedure.
11. 11

    Final safety verification
    Perform final walk-around verification: service disconnect is removed and secured with lock-out device at least 10 feet from vehicle; orange safety barrier is installed in vehicle receptacle; 10+ minutes have elapsed since disconnect; voltage verified below 10V DC; warning signs are posted; 12V battery remains connected; all required PPE is available for ongoing work. Only after all verifications are complete may high voltage service work begin.

Reassembly

1. Before reconnecting, inspect the service disconnect assembly contacts for any damage, corrosion, or contamination
2. Verify the high voltage receptacle in the vehicle is clean and dry with no foreign objects
3. Remove the orange safety barrier plug from the vehicle receptacle
4. Remove the lock-out device from the service disconnect assembly
5. Align the service disconnect assembly with the receptacle, ensuring proper keying and orientation
6. Push the disconnect straight in firmly until fully seated (you should feel it bottom out)
7. Rotate the handle clockwise 90 degrees to lock the disconnect in place
8. Verify the disconnect is fully locked by attempting to pull it out (it should not move)
9. Reinstall the access panel cover and secure all retaining clips
10. Remove all lock-out/tag-out devices and warning signs
11. Using diagnostic tool, clear any stored disconnect fault codes if present

Verification

• With diagnostic tool connected, power on the vehicle and verify the high voltage system initializes without faults
• Check that the instrument cluster shows 'READY' status and no high voltage warning indicators
• Verify the vehicle can shift into Drive and Reverse (do not drive yet)
• Monitor the diagnostic tool for proper high voltage system voltage (approximately 350-800V DC depending on state of charge)
• Perform a low-speed test drive in a safe area and verify normal operation of both drive motors
• Verify regenerative braking functions normally
• Check for any new fault codes related to high voltage system
• Verify all high voltage service disconnect warnings are cleared from the instrument cluster
• Test charge port functionality if service work involved charging system components

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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