Inverter R&R

This procedure covers the removal and replacement of the inverter assembly on a 2024 Rivian EDV 500 electric delivery van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Inverter assembly × 1 — Use OEM specification
• Inverter coolant seal O-rings × 2 — Use OEM specification
• High voltage connector seals × 2 — Use OEM specification
• Inverter mounting gasket × 1 — Use OEM specification
• High voltage interlock connector × 1 — 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 powered down for minimum 2 hours to allow coolant system to cool
3. Connect Rivian diagnostic interface and place high voltage system in service mode
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
5. Document all electrical connector positions with photos before disconnection
6. Remove front underbody panels to access inverter compartment
7. Place high voltage warning tags on steering wheel and charge port

Procedure

1. 1

   Disable high voltage system
   Using Rivian diagnostic software, command the high voltage system into safe service mode. Verify that the vehicle confirms high voltage isolation. Remove the high voltage service disconnect located in the rear cargo area by removing the access panel, then pulling the orange service disconnect handle straight up. Install lockout/tagout device on the service disconnect location.
2. 2

   Verify high voltage isolation
   Wait minimum 15 minutes for capacitor discharge. Using a calibrated high voltage multimeter, verify zero voltage at the inverter high voltage terminals. Test between positive and negative terminals, then test each terminal to chassis ground. All readings must be below 5V DC before proceeding.
3. 3

   Drain coolant system
   Place drain pan beneath inverter coolant connections. Locate the coolant drain valve on the inverter cooling loop (lower front corner of inverter housing). Slowly open the drain valve and allow EV Battery/Motor Coolant to drain completely into the pan. Close drain valve when flow stops. Mark and photograph coolant hose routing for reinstallation reference.
4. 4

   Disconnect coolant lines
   Disconnect the inlet and outlet coolant lines from the inverter assembly. Use two wrenches to prevent twisting the inverter-mounted fittings. Cap or plug all open coolant connections immediately to prevent contamination. Remove and discard the coolant seal O-rings.
5. 5

   Remove high voltage connections
   Wearing high voltage insulated gloves, remove the orange high voltage connector covers from both the front and rear motor cables. Remove the high voltage interlock connector (small 2-pin connector on main HV connector). Mark the front motor and rear motor cable positions with tags. Remove the mounting bolts securing each high voltage cable to the inverter. Carefully position cables away from inverter housing.
6. 6

   Disconnect low voltage connectors
   Locate and disconnect all low voltage control connectors on the inverter assembly. This includes: main control connector (large gray 48-pin connector), temperature sensor connectors (2), resolver/encoder feedback connectors (2), and communication bus connector (black 4-pin connector). Mark each connector position with wire tags corresponding to your photos.
7. 7

   Remove inverter ground connections
   Locate the inverter chassis ground connections on the left side of the inverter housing. Remove the ground strap mounting bolts and carefully position ground straps aside. Note the exact mounting sequence and orientation of ground lugs for reinstallation.
8. 8

   Support inverter assembly
   Position a transmission jack or dedicated inverter support fixture beneath the inverter housing. Adjust the support to contact the bottom of the inverter housing evenly. Apply slight upward pressure to support the weight of the inverter before removing mounting bolts.
9. 9

   Remove inverter mounting hardware
   Locate and remove all inverter mounting bolts. There are typically 8 primary mounting bolts securing the inverter to the drive unit housing. Remove bolts in a cross-pattern sequence to maintain even support. Keep track of bolt locations as some may be different lengths.
10. 10

    Remove inverter assembly
    With the support fixture in place, carefully lower the inverter assembly away from the drive unit housing. Guide the unit clear of all remaining connections and mounting points. The inverter will separate along with its mounting gasket. Lower the assembly completely and move to a clean work surface. Inspect the inverter mounting surface on the drive unit for damage or debris.
11. 11

    Prepare new inverter
    Remove the new inverter from packaging and inspect for shipping damage. Install new coolant seal O-rings onto the inverter coolant ports using EV coolant as lubricant. Install new high voltage connector seals onto the inverter HV terminals. Position the new inverter mounting gasket onto the drive unit housing, ensuring proper alignment with all mounting holes.
12. 12

    Install new inverter assembly
    Using the support fixture, carefully raise the new inverter assembly into position against the drive unit housing. Align the inverter with the mounting gasket and ensure all alignment dowels engage properly. Guide the assembly to avoid pinching any remaining wiring or coolant lines.
13. 13

    Install mounting hardware
    Install all inverter mounting bolts finger-tight initially. Once all bolts are started, tighten in a cross-pattern sequence to ensure even clamping of the mounting gasket. Without specific torque values provided, use calibrated torque wrench and follow standard electrical component mounting practices. Record torque values applied for service documentation.
14. 14

    Reconnect electrical connections
    Reconnect all low voltage control connectors in reverse order of removal, using your photos and wire tags as reference. Ensure each connector fully seats and locking tabs engage. Reconnect inverter chassis ground connections with ground straps in original mounting sequence. Reconnect high voltage cables to inverter, installing new high voltage interlock connector. Ensure HV cable mounting bolts are properly torqued and install orange HV connector covers.
15. 15

    Reconnect coolant system and refill
    Connect inverter coolant inlet and outlet lines with new O-rings installed. Tighten fittings while supporting inverter-mounted connections. Fill the EV coolant system with fresh EV Battery/Motor Coolant through the designated fill port. Fill system to proper level (approximately 10 quarts total capacity). Use Rivian diagnostic software to command coolant pump operation and purge air from the system. Top off coolant as needed and verify no leaks at inverter connections.

Reassembly

1. Reinstall all front underbody panels removed during disassembly
2. Remove lockout/tagout device and reinstall high voltage service disconnect
3. Reconnect 12V auxiliary battery negative terminal
4. Clear any stored high voltage isolation fault codes using diagnostic software
5. Perform inverter configuration and calibration using Rivian diagnostic software as required

Verification

• Use Rivian diagnostic software to verify high voltage system integrity and proper isolation resistance (should exceed 500 ohms/volt)
• Command the vehicle to ready mode and verify inverter operates without fault codes
• Monitor inverter temperature sensors during initial operation to verify proper coolant flow
• Perform controlled test drive at low speeds to verify proper motor control and torque response from both front and rear motors
• Inspect all coolant connections for leaks after test drive with system at operating temperature
• Verify no high voltage fault codes present and all inverter parameters are within normal operating ranges
• Document inverter serial number and software version in vehicle service records

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