This procedure covers the removal and replacement of the DC-DC converter on the 2025 Rivian EDV 500, which converts high voltage battery power to 12V for vehicle accessories.

Warnings

Tools required

Parts

• DC-DC converter assembly × 1 — Use OEM specification
• High voltage connector seals (if equipped) × 2 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification
• Thermal interface compound × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Turn off vehicle and remove key fob from passenger compartment
3. Disconnect 12V auxiliary battery negative terminal and isolate
4. Access the Rivian diagnostic system and initiate high voltage system shutdown procedure
5. Remove front underbody panels to access DC-DC converter location
6. Place warning tags on steering wheel indicating high voltage work in progress
7. Don high voltage safety gloves and safety equipment
8. Verify all high voltage service procedures are understood before proceeding

Procedure

1. 1

   De-energize high voltage system
   Locate the high voltage service disconnect located in the rear cargo area. Remove the access panel and carefully pull the service disconnect handle to the OFF position. Install the provided locking pin to prevent reconnection. Place the service disconnect key in your possession throughout the repair.
2. 2

   Verify system de-energization
   Wait minimum 10 minutes for capacitor discharge. Using a calibrated high voltage multimeter, verify zero voltage across all high voltage terminals at the DC-DC converter input connector. Document voltage reading as 0V before proceeding. Check between each phase conductor and vehicle ground.
3. 3

   Drain cooling system
   Position coolant drain pan beneath DC-DC converter. Locate the coolant drain valve on the low-temperature cooling circuit. Attach drain hose and open valve to drain coolant from the system. Allow system to drain completely, collecting approximately 2 quarts of coolant. Cap or plug the drain valve when complete.
4. 4

   Disconnect coolant lines
   Using hose clamp pliers, release the spring clamps on both coolant inlet and outlet hoses at the DC-DC converter. Carefully remove hoses, allowing any residual coolant to drain into pan. Inspect hose ends for damage or deterioration. Plug open coolant ports on converter to prevent contamination.
5. 5

   Disconnect low voltage output
   Locate the 12V output connector on the DC-DC converter. Depress the locking tab and carefully disconnect the multi-pin connector. Move connector aside and secure to prevent damage. Inspect connector terminals for corrosion or damage.
6. 6

   Disconnect high voltage input connector
   While wearing high voltage gloves, locate the high voltage input connector (orange cable assembly) at the DC-DC converter. Release the safety locking mechanism by pressing the release tab. Carefully pull connector straight out from converter housing without twisting. Cover exposed terminals with provided insulating caps. Secure cable away from work area.
7. 7

   Remove mounting hardware
   Locate all DC-DC converter mounting bolts (typically 4-6 bolts securing unit to mounting bracket). Remove mounting bolts in a cross pattern to prevent binding. Note any ground straps or bonding connections that must be transferred to new unit. Support converter weight during removal as unit weighs approximately 15-20 lbs.
8. 8

   Remove DC-DC converter
   Carefully lift DC-DC converter from mounting bracket, ensuring all connections are free. Maneuver unit out of vehicle, taking care not to damage surrounding components or wiring harnesses. Place old unit on clean work surface for comparison with replacement.
9. 9

   Prepare replacement converter
   Unpack new DC-DC converter and verify correct part number matches vehicle specification. Inspect all connector ports for shipping covers and remove as needed. Check mounting bracket interface surfaces and clean if necessary. Apply thermal interface compound to mounting surfaces if specified by manufacturer.
10. 10

    Install new DC-DC converter
    Position new DC-DC converter into mounting bracket, aligning all mounting holes. Verify coolant ports are oriented correctly and connectors are accessible. Hand-thread all mounting bolts to prevent cross-threading. Tighten mounting bolts in cross pattern to ensure even seating. Reattach any ground straps in original locations.
11. 11

    Reconnect high voltage input
    Remove insulating caps from high voltage connector. Inspect connector seals and replace if damaged. While wearing high voltage gloves, align connector with DC-DC converter input port and press firmly until safety lock engages with audible click. Verify connector is fully seated and locked.
12. 12

    Reconnect low voltage output
    Connect the 12V output multi-pin connector to DC-DC converter, ensuring proper alignment. Press connector until locking tab clicks into place. Verify secure connection by gently pulling on connector body.
13. 13

    Reconnect coolant system
    Remove plugs from coolant ports on new DC-DC converter. Install coolant hoses onto inlet and outlet ports, ensuring hoses are fully seated onto barbed fittings. Install new spring clamps or hose clamps at each connection point. Verify clamps are positioned correctly over barbed sections.
14. 14

    Refill cooling system
    Using specified EV Battery/Motor Coolant, refill the low-temperature cooling circuit through the fill port. Add approximately 2 quarts or until coolant reaches proper level on reservoir. Burp cooling system by running coolant pump if vehicle system allows. Check for leaks at all connection points.
15. 15

    System verification and testing
    Reconnect 12V auxiliary battery. Remove service disconnect locking pin and return high voltage service disconnect to ON position. Connect Rivian diagnostic software and clear any stored fault codes. Initialize DC-DC converter through guided diagnostic procedure. Monitor DC-DC converter output voltage - should read approximately 13.5-14.5V. Check for proper cooling system operation and verify no coolant leaks. Perform a test drive and monitor all vehicle systems for proper operation.

Reassembly

1. Reinstall all underbody panels removed during access
2. Remove high voltage work warning tags
3. Verify all tools and parts have been removed from vehicle
4. Check coolant level after initial operation and top off if necessary
5. Reset any service indicators using diagnostic software

Verification

• Verify 12V system voltage reads 13.5-14.5V with vehicle in RUN mode using multimeter
• Confirm no high voltage fault codes present in diagnostic system
• Check for coolant leaks around DC-DC converter connections with system at operating temperature
• Verify all low voltage accessories function properly (lights, HVAC, infotainment)
• Monitor DC-DC converter temperature during test drive - should remain within normal operating range
• Confirm 12V battery charging indicator shows proper charging status on instrument cluster

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