Battery Disconnect Service

This procedure safely disconnects the high-voltage battery system on the 2025 Rivian EDV 500, isolating electrical power for service work requiring battery de-energization.

Warnings

Tools required

Parts

• High-voltage connector seals (if damaged) × 1 — Use OEM specification
• Service plug cover (if damaged) × 1 — Use OEM specification

Preparation

1. Verify technician has completed high-voltage safety training and certification
2. Inspect high-voltage gloves for cuts, tears, or other damage. Do not use if damaged
3. Park vehicle on level surface, apply parking brake firmly, and place wheel chocks
4. Place warning cone or sign near vehicle indicating high-voltage service in progress
5. Ensure 12V battery is fully charged (low-voltage system must remain operational for some steps)
6. Connect Rivian diagnostic software to vehicle
7. Document any existing fault codes in vehicle system
8. Remove any jewelry, watches, or conductive items from hands and wrists
9. Ensure fire extinguisher rated for electrical fires is nearby

Procedure

1. 1

   Power down vehicle systems
   Press the power button to turn off the vehicle completely. Verify all displays are dark and vehicle is in park. Wait 30 seconds for all systems to enter sleep mode. Using diagnostic software, command the vehicle into service mode to prevent automatic wake-up functions.
2. 2

   Disconnect 12V auxiliary battery
   Open the front hood. Locate the 12V auxiliary battery in the front compartment. Using a 10mm socket, disconnect the negative terminal first, then the positive terminal. Isolate terminals to prevent accidental reconnection. This prevents the low-voltage system from attempting to energize vehicle systems during service.
3. 3

   Access high-voltage service disconnect location
   Open the rear cargo doors. Remove the rear cargo floor panel by releasing the clips. The high-voltage service disconnect is located at the rear of the battery pack assembly, accessible from the cargo area. Remove any covers or panels securing access to the service disconnect using appropriate panel tools.
4. 4

   Don high-voltage personal protective equipment
   Put on insulated high-voltage gloves rated Class 0 or higher. Verify gloves are dry and undamaged. Ensure long sleeves cover any gap between gloves and clothing. Do not proceed without proper PPE.
5. 5

   Remove high-voltage service disconnect plug
   Locate the orange high-voltage service disconnect handle. Rotate the handle counterclockwise approximately 45 degrees to unlock. Pull the disconnect plug straight out with firm, steady pressure. The plug contains the high-voltage interlock circuit and physically disconnects the battery pack. Store the service plug in a secure location away from the vehicle.
6. 6

   Install lockout/tagout on service disconnect
   Install a lockout device on the service disconnect location to prevent accidental reinstallation. Attach a service tag indicating high-voltage disconnect status, technician name, and date. This prevents others from reconnecting the system while service is in progress.
7. 7

   Wait for capacitor discharge period
   Wait a minimum of 5 minutes with the service disconnect removed. This allows high-voltage capacitors in the drive units and DC-DC converter to fully discharge. Set a timer and do not proceed until the full 5 minutes has elapsed. During this time, do not touch any high-voltage components.
8. 8

   Verify high-voltage system de-energization
   Using a high-voltage rated digital multimeter, verify zero voltage at the high-voltage busbar connections. With insulated gloves still on, measure voltage between the positive and negative high-voltage terminals. Voltage should read less than 5V DC. Also verify zero voltage between each terminal and vehicle chassis ground. Do not proceed if any voltage above 5V is detected.
9. 9

   Disconnect high-voltage interlocks (if required)
   If service requires additional isolation, locate and disconnect the orange high-voltage interlock connectors at the drive units. Press the release tab and pull the connector straight out. These interlocks are part of the safety system and should only be disconnected if necessary for the specific repair.
10. 10

    Disconnect main high-voltage contactors (if required)
    For service requiring complete battery pack isolation, access the main contactor assembly on top of the battery pack. Remove the protective cover by releasing the retaining clips. Disconnect the high-voltage cable connections at the contactors using appropriate sized sockets. Support cables to prevent strain on connections. Keep disconnected cables separated and insulated.
11. 11

    Document disconnection status
    Take photographs of all disconnected high-voltage components and their positions. Document the disconnection in the vehicle service record using diagnostic software. Note the exact time of disconnection and verification measurements. This documentation is critical for safety and reconnection procedures.
12. 12

    Secure work area
    Cover any exposed high-voltage terminals with insulating covers or tape. Ensure service disconnect plug is stored in a secure location where it cannot be accidentally reinstalled. Verify lockout/tagout devices are properly installed. Update warning signs around vehicle to indicate high-voltage disconnect status. Vehicle is now safe for service requiring battery disconnection.

Reassembly

1. Before reconnection, inspect all high-voltage connectors, seals, and terminals for damage, corrosion, or contamination. Replace any damaged components.
2. Apply fresh dielectric grease to high-voltage connector terminals before reconnection.
3. Reconnect main high-voltage contactors (if disconnected) and torque fasteners per service manual specifications.
4. Reconnect high-voltage interlock connectors ensuring positive engagement with audible click.
5. Remove lockout/tagout devices from service disconnect location.
6. Align and insert high-voltage service disconnect plug straight into receptacle until seated, then rotate clockwise 45 degrees to lock.
7. Verify service disconnect cover is properly installed and secured.
8. Reinstall cargo floor panels and any removed interior components.
9. Reconnect 12V auxiliary battery: positive terminal first, then negative terminal.
10. Use diagnostic software to clear any fault codes and verify high-voltage system integrity before powering vehicle.
11. Perform system initialization and verify no high-voltage fault codes present.

Verification

• Connect diagnostic software and verify no high-voltage system fault codes are present.
• Power on the vehicle and verify the instrument cluster does not display any high-voltage warnings.
• Check that the vehicle is ready to drive with full propulsion available.
• Verify high-voltage battery state of charge is displayed correctly on instrument cluster.
• Perform a low-speed drive test to confirm normal operation of both drive motors.
• Using diagnostic software, monitor high-voltage system parameters to ensure all voltages and temperatures are within normal range.
• Verify regenerative braking functions normally during test drive.
• Document completion of battery disconnect service and verification in vehicle service records.

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