EV Annual Inspection

Comprehensive annual safety and maintenance inspection of the 2025 Rivian EDV 500 electric delivery vehicle, covering high-voltage systems, battery health, brake system, suspension, tires, and all critical EV components.

Warnings

Tools required

Parts

• Cabin air filter × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off vehicle completely and remove key fob from vehicle interior
3. Allow high-voltage system to de-energize (wait minimum 5 minutes after shutdown)
4. Verify 12V service battery voltage is above 12.4V before proceeding
5. Don Class 0 insulated gloves when inspecting near high-voltage components
6. Safely lift vehicle and secure on jack stands rated for commercial vehicle weight
7. Chock rear wheels if inspecting front, or front wheels if inspecting rear

Procedure

1. 1

   High-Voltage System Visual Inspection
   With vehicle powered off, visually inspect all high-voltage orange cabling for damage, chafing, or exposed conductors. Inspect high-voltage battery enclosure for physical damage, corrosion, or signs of coolant/moisture intrusion. Check battery mounting bolts and structural supports for integrity. Inspect charge port door, locking mechanism, and weatherseals for damage.
2. 2

   Battery Management System Diagnostics
   Connect OBD-II scanner with EV diagnostic capability to vehicle diagnostic port. Power on vehicle to accessory mode. Retrieve and document any stored diagnostic trouble codes. Review battery state of health (SOH), individual cell voltage balance (all cells should be within 0.1V of each other), battery temperature sensors, and charge cycle count. Check for any thermal management system faults. Document current battery capacity percentage.
3. 3

   Thermal Management System Inspection
   Inspect EV battery/motor coolant reservoir level and condition. Coolant should be clean with no discoloration or debris. Check coolant freeze point protection using hydrometer (should protect to -40°F). Inspect all visible coolant hoses, connections, and radiator for leaks, damage, or deterioration. Check electric coolant pump mounting and wiring connections. Inspect thermal management system radiator and condenser for debris or damage.
4. 4

   Drive Unit and Differential Inspection
   Inspect front and rear drive units for fluid leaks around seals and gaskets. Check differential breather vents are clear and not obstructed. Visually inspect drive unit mounting bolts and bushings for damage or excessive wear. Check CV axle boots for tears, cracks, or grease leakage. Inspect drive shafts for damage or runout.
5. 5

   Brake System Inspection
   Measure brake pad thickness at all four corners; replace if less than 3mm remaining. Inspect brake rotors for scoring, cracking, or excessive wear. Measure rotor thickness and compare to minimum specification stamped on rotor. Check brake calipers for fluid leaks, proper sliding pin movement, and corrosion. Test brake fluid moisture content using test strips; fluid should be below 3% moisture. Inspect brake lines and hoses for damage, chafing, or deterioration.
6. 6

   Regenerative Braking System Test
   Using diagnostic scanner, verify regenerative braking system is functioning properly. Check for any regen system fault codes. Review brake blending system operation (transition between regenerative and friction braking). Verify brake pedal feel sensor readings are within normal parameters. Document maximum regenerative braking torque available.
7. 7

   Suspension and Steering Inspection
   Inspect front and rear suspension components including control arms, ball joints, tie rod ends, and bushings for wear, damage, or excessive play. Check shock absorbers for fluid leaks or physical damage. Inspect steering rack boots for tears or grease leaks. Verify electric power steering system operates smoothly with no abnormal noises. Check wheel bearings for play by attempting to rock each wheel with hands at 12 and 6 o'clock positions.
8. 8

   Tire and Wheel Inspection
   Measure tire tread depth at multiple points on each tire; minimum legal depth is 2/32 inch but replace at 4/32 inch for commercial vehicles. Inspect tires for uneven wear patterns, cuts, bulges, or embedded objects. Check tire pressures when cold and adjust to specification on door placard (typically 70-80 PSI for commercial EV). Inspect wheels for cracks, bends, or damage. Verify lug nuts are properly torqued and check for missing or damaged lug nuts.
9. 9

   12V Electrical System Check
   Test 12V service battery voltage and load test if voltage is below 12.6V. Inspect battery terminals for corrosion and ensure tight connections. Check DC-DC converter operation (converts high-voltage to 12V). Test all exterior lighting including headlights, taillights, brake lights, turn signals, and hazard lights. Verify backup camera and sensors function properly. Test horn operation. Check wiper operation and washer fluid level.
10. 10

    HVAC and Cabin Systems Inspection
    Inspect and replace cabin air filter if dirty or restricted. Test HVAC system operation in heating and cooling modes. Verify climate control responds properly to inputs. Check for unusual odors or reduced airflow. Inspect cabin for any water intrusion or moisture. Test all interior lighting and instrument cluster displays.
11. 11

    Body and Cargo Area Inspection
    Inspect cargo area floor and walls for damage or excessive wear. Check cargo door hinges, latches, and seals for proper operation and weatherproofing. Verify cargo tie-down points are secure. Inspect exterior body panels for collision damage or corrosion. Check mirrors, door handles, and exterior trim for damage or looseness. Verify all doors, hood, and panels close and latch properly.
12. 12

    Safety Systems Verification
    Using diagnostic scanner, verify operation of all safety systems including ABS, traction control, stability control, and collision avoidance systems. Check for any fault codes in safety system modules. Verify all airbag systems show ready status with no faults. Test parking brake holding force and electronic parking brake operation. Verify seatbelt pretensioners show no faults.
13. 13

    Underbody and Frame Inspection
    Thoroughly inspect vehicle underbody for damage from road debris or impacts. Check frame rails and crossmembers for cracks, bends, or corrosion. Inspect exhaust heat shield (if equipped) and underbody protective panels for secure mounting. Check for any loose fasteners or hardware. Inspect for any fluid leaks or staining on underbody components.

Reassembly

1. Lower vehicle from jack stands and remove chocks
2. Verify all inspection panels and access covers are properly secured
3. Top off windshield washer fluid to proper level
4. Clear any diagnostic trouble codes that were addressed during inspection
5. Reset service interval reminder if equipped

Verification

• Power on vehicle and verify no new warning lights or messages appear on instrument cluster
• Verify charging system operates normally by plugging in charge cable and confirming charge initiation
• Perform test drive to verify proper operation of all systems including acceleration, regenerative braking, steering, and handling
• Verify all electrical accessories and lighting function properly
• Complete inspection checklist documenting all findings and recommendations
• Provide customer with detailed inspection report including battery health status, recommended services, and any safety concerns

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