Regenerative Braking Calibration

This procedure calibrates the regenerative braking system on the 2024 Rivian EDV 500 to ensure optimal brake energy recovery and seamless integration between regenerative and friction braking.

Warnings

Tools required

Parts

• No consumable parts required for calibration — N/A

Preparation

1. Verify battery state of charge is between 20% and 80% for accurate calibration
2. Ensure vehicle is parked on level ground with parking brake released
3. Place wheel chocks behind rear wheels for safety
4. Verify no brake system DTCs are present before beginning calibration
5. Confirm brake fluid level is within specification (DOT 4)
6. Connect laptop with Rivian Diagnostic Software to vehicle OBD-II port
7. Establish stable communication with vehicle control modules
8. Close all vehicle doors and ensure driver seatbelt is fastened for calibration test cycles

Procedure

1. 1

   Initialize Diagnostic Connection
   Launch Rivian Diagnostic Software and select '2024 EDV 500 Dual Motor AWD' from vehicle selection menu. Navigate to 'Brake Systems' > 'Regenerative Braking Module'. Verify communication with the following modules: Brake Control Module (BCM), Front Drive Unit (FDU), Rear Drive Unit (RDU), and Battery Management System (BMS). Record any existing fault codes before proceeding.
2. 2

   Perform Pre-Calibration System Check
   Run the automated pre-calibration diagnostic test in RDS. This checks motor resolver alignment, brake pedal position sensor range, brake pressure sensor calibration, and battery thermal management status. All checks must pass with 'OK' status before continuing. If any check fails, address the specific fault before proceeding with regenerative braking calibration.
3. 3

   Clear Adaptive Regenerative Braking Data
   Navigate to 'Service Functions' > 'Clear Adaptive Data' > 'Regenerative Braking'. Select 'Clear All Adaptive Learning Values'. This resets previous driving style adaptations and brake blending preferences. Confirm the operation when prompted. Wait for confirmation message indicating adaptive data has been successfully cleared.
4. 4

   Calibrate Brake Pedal Position Sensors
   Select 'Calibration Procedures' > 'Brake Pedal Position Sensor Calibration'. Follow on-screen prompts: ensure brake pedal is fully released, press 'Continue' to capture zero position. Slowly depress brake pedal to floor and hold for 3 seconds to capture maximum travel position. Release pedal completely. System will verify a minimum 15-degree travel range. Repeat if calibration fails.
5. 5

   Calibrate Brake Pressure Sensors
   With brake pedal fully released, select 'Brake Pressure Sensor Zero Calibration'. System will sample hydraulic pressure sensor readings for 10 seconds with pedal released. Do not touch brake pedal during this time. Next, apply moderate brake pressure (approximately 30-40% pedal travel) when prompted and hold steady for 5 seconds. Release pedal when instructed. System will confirm successful calibration.
6. 6

   Set Regenerative Braking Blending Parameters
   Navigate to 'Regenerative Braking Configuration'. Verify the following parameters are set to factory specification: Max Regen Torque Front = 240 Nm, Max Regen Torque Rear = 340 Nm, Blending Transition Speed = 5 mph, Friction Brake Activation Threshold = 0.3g deceleration. These values are specific to the EDV 500 commercial application. Do not modify unless directed by Rivian engineering bulletin.
7. 7

   Execute Static Regeneration Test
   Select 'Static System Tests' > 'Regeneration Capability Test'. System will command both drive units into regeneration mode at standstill to verify electrical path integrity. Monitor test results showing front motor regen capacity, rear motor regen capacity, and battery acceptance rate. All values should be within 5% of nominal specification. Test duration is approximately 30 seconds.
8. 8

   Perform Dynamic Calibration Drive Cycle
   Select 'Dynamic Calibration' > 'Regenerative Brake Drive Cycle'. System will provide on-screen instructions for a low-speed calibration drive. On a safe, flat surface with at least 100 feet of clear space, accelerate vehicle to 15 mph, then release accelerator pedal completely and allow regenerative braking to slow vehicle naturally. Repeat this cycle 5 times as directed by software. System monitors brake blending transition points during each cycle.
9. 9

   Calibrate Brake Blending Algorithm
   With dynamic drive cycle data collected, select 'Execute Brake Blending Calibration'. Software analyzes the regenerative to friction brake transition characteristics and optimizes blending algorithm for smooth deceleration. This process takes approximately 3-5 minutes. Do not interrupt or disconnect diagnostic tool during this calculation phase. Progress bar will indicate calibration status.
10. 10

    Verify Calibration and Write Data
    Review calibration summary screen showing all calibrated parameters and confidence levels (should all be >95%). Select 'Write Calibration to Vehicle'. System will flash updated calibration data to Brake Control Module, Front Drive Unit, and Rear Drive Unit. This takes approximately 2 minutes. Do not turn off vehicle or disconnect power during flash process. Wait for 'Calibration Successfully Written' confirmation.
11. 11

    Perform Post-Calibration Verification Test
    Run the automated post-calibration verification test. System will command a series of regenerative braking events at virtual load to verify: proper motor response, brake blending transition smoothness, hydraulic pressure sensor accuracy, and overall system coordination. All tests must pass. If any test fails, review fault codes and repeat relevant calibration steps.
12. 12

    Road Test Validation
    Perform a controlled road test to validate regenerative braking calibration. Drive vehicle on a safe route at speeds up to 45 mph. Test regenerative braking at various speeds and pedal applications. Verify smooth transitions between regenerative and friction braking with no pedal pulsation, jerking, or unusual noise. Test one-pedal driving mode if equipped. Monitor brake system status in RDS during test drive for any anomalies.

Reassembly

1. Disconnect diagnostic equipment from OBD-II port
2. Remove wheel chocks
3. Verify parking brake operates correctly
4. Reset trip computer or driver display if needed to clear any calibration messages
5. Document calibration completion in vehicle service records with date, mileage, and software version

Verification

• Confirm no brake system DTCs are present after calibration
• Verify regenerative braking engages smoothly when accelerator pedal is released at various speeds
• Test that friction brakes blend seamlessly with regenerative braking under moderate to heavy braking
• Confirm brake pedal feel is consistent and progressive with no dead spots
• Verify regenerative braking charge indicator displays correctly on instrument cluster during deceleration
• Test that ABS and stability control systems function properly during emergency braking scenarios
• Print calibration report from RDS showing all parameters within specification and save to vehicle file

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