This procedure covers the removal and replacement of a high voltage battery module in a 2025 Rivian EDV 500, including disconnection of high voltage systems, coolant drainage, module extraction, and system reactivation.

Warnings

Tools required

Parts

• High voltage battery module assembly × 1 — Use OEM specification - module specific to pack configuration
• HV battery module thermal interface pads × 1 — Use OEM specification
• Module coolant line O-rings × 1 — Use OEM specification
• HV connector seal kit × 1 — Use OEM specification
• Battery module mounting hardware kit × 1 — Use OEM specification
• Service disconnect plug lockout tag × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface in well-ventilated area away from ignition sources
2. Verify vehicle is in Park and apply parking brake
3. Allow vehicle to sit unpowered for minimum 30 minutes to allow capacitors to discharge
4. Don all personal protective equipment including insulated gloves, face shield, and arc-rated clothing
5. Place high voltage safety mat on ground at driver side work area
6. Connect Rivian diagnostic scan tool and log into service mode
7. Using scan tool, command HV battery system to safe mode and verify system is disabled
8. Open front trunk (frunk) and locate 12V service battery disconnect - disconnect negative terminal
9. Wait additional 15 minutes after 12V disconnect for all vehicle systems to power down completely
10. Place wheel chocks at all four wheels
11. Locate high voltage service disconnect under rear cargo area access panel - remove and install lockout tag
12. Using high voltage multimeter, verify 0V DC at service disconnect terminals (confirm at least 3 times)
13. Raise vehicle on lift to comfortable working height
14. Remove underbody aero panels to access battery pack (retain all fasteners)

Procedure

1. 1

   Verify High Voltage Isolation
   With insulated gloves on, use high voltage multimeter to test voltage at multiple points: battery main positive busbar to chassis ground, battery negative to chassis ground, and across main contactor terminals. All readings must be 0V DC. If any voltage is present, stop procedure and investigate cause. Re-verify service disconnect is removed and wait additional 30 minutes.
2. 2

   Drain Battery Thermal Management Coolant
   Locate battery coolant drain valve on underside of pack. Position 12-quart drain pan beneath drain point. Open drain valve using 10mm socket. Allow coolant to drain completely (approximately 10-15 minutes). Close drain valve. Note coolant condition - if contaminated or discolored, entire cooling system should be flushed. Dispose of used coolant according to local regulations.
3. 3

   Disconnect Battery Thermal Coolant Lines
   Locate coolant quick-disconnect fittings at battery module connections. Release locking tabs and carefully disconnect coolant supply and return lines from module being replaced. Cap open coolant lines immediately to prevent contamination. Inspect O-rings on disconnected fittings and replace if damaged. Allow residual coolant to drain into pan.
4. 4

   Remove Battery Management System Wiring
   Locate BMS sensor harness connector on target battery module. Carefully depress connector locking tab and pull connector straight out - do not twist. Tag connector position for reassembly reference. Inspect connector pins for corrosion or damage. Remove any cable tie retention points securing harness to module or adjacent components.
5. 5

   Disconnect Module High Voltage Bus Connections
   Wearing insulated gloves, locate HV bus bar connections at top of battery module. Use scan tool to verify one final time that pack voltage is 0V. Remove HV connector cover plates. Using appropriate socket (typically 13mm), remove bus bar bolts connecting module to adjacent modules and main pack bus. Carefully lift bus bars away from module terminals. Cover exposed HV terminals with insulating caps. Store bus bar hardware in organized manner noting orientation and position.
6. 6

   Remove Module Retention Hardware
   Locate battery module mounting bolts around perimeter of module (typically 8-12 bolts depending on module position). Using torque wrench in loosening direction, break torque on all bolts before fully removing any. Remove bolts in crossing pattern (similar to wheel lug pattern) to prevent binding. Keep all hardware organized by position. Remove any side retention brackets or compression plates securing module to pack structure.
7. 7

   Extract Battery Module from Pack
   Position battery lift table or transmission jack under target module. Carefully raise lift to contact bottom of module - do not apply lifting force yet. Verify all connections and fasteners have been removed. With assistant support, slowly lower module onto lift table while guiding clear of adjacent modules and pack structure. Module may require slight tilting or rotation to clear internal structures. Once free, carefully roll lift table out from under vehicle. Move module to safe storage area on insulated surface away from work area.
8. 8

   Inspect Battery Pack Interior and Prepare for New Module
   With module removed, inspect battery pack interior for any coolant leaks, corrosion, foreign debris, or damage. Clean module mounting surfaces with lint-free cloth - ensure surfaces are completely clean and dry. Inspect thermal interface pad mounting areas on pack floor and cooling plate. Remove old thermal interface pads completely. Verify adjacent modules show no signs of damage or swelling. Check all visible HV connections for corrosion or overheating indicators.
9. 9

   Prepare New Battery Module
   Unpack new battery module following Rivian handling procedures - keep in insulated container until ready to install. Verify module part number matches removed unit and is correct for vehicle pack configuration. Apply new thermal interface pads to bottom of new module per Rivian service documentation - ensure full contact area coverage with no air gaps or wrinkles. Install new O-rings on coolant connection ports if not pre-installed. Verify BMS connector on new module is clean and undamaged.
10. 10

    Install New Battery Module
    Position new module on lift table. Carefully roll lift table under vehicle and align module with mounting location in battery pack. Raise lift table slowly while guiding module into position - ensure coolant ports and HV terminals align with mating connections. Do not force module - if resistance is felt, lower and realign. Once fully seated, verify module sits flush against thermal interface pads with no gaps. Begin threading mounting bolts by hand to prevent cross-threading.
11. 11

    Torque Module Retention Hardware
    Install all module mounting bolts finger-tight first. Once all bolts are started, torque in crossing pattern to manufacturer specification in three stages: 50% spec, 75% spec, then final spec. Without verified torque specifications in database, do not exceed conservative estimate of 15-20 ft-lb for module mounting bolts - consult Rivian service documentation for exact values. Reinstall any side retention brackets or compression plates removed earlier.
12. 12

    Reconnect High Voltage Bus Connections
    Remove insulating caps from HV terminals. Inspect bus bar contact surfaces and clean if necessary with electrical contact cleaner. Position HV bus bars onto module terminals ensuring correct orientation and full contact. Install bus bar mounting bolts and torque to specification - without verified spec, use conservative 10-12 ft-lb and mark for verification with Rivian documentation. Reinstall HV connector cover plates. Apply dielectric grease to cover plate seals if specified.
13. 13

    Reconnect BMS Wiring and Coolant Lines
    Reconnect BMS sensor harness to new module - push connector until positive click is heard and locking tab engages. Gently tug connector to verify secure connection. Reinstall cable tie retention points. Remove caps from coolant lines. Connect coolant supply and return lines to module quick-disconnect fittings - push firmly until locking tabs click. Verify secure connection by attempting to pull lines off with moderate force.
14. 14

    Refill and Bleed Battery Cooling System
    Using vacuum-fill coolant system kit, evacuate air from battery thermal management system per equipment instructions. Fill system with new EV Battery/Motor Coolant to proper level (approximately 2 quarts to replace module circuit volume). Start vacuum fill process to draw coolant into system without introducing air. Once filled, close coolant drain valve. Run coolant pump activation procedure through scan tool to circulate coolant and purge remaining air. Check coolant level and top off as needed. Inspect all coolant connections for leaks.
15. 15

    Commission New Module and Perform System Tests
    Reinstall underbody aero panels with all fasteners. Lower vehicle to ground. Reinstall high voltage service disconnect plug (do NOT install lockout tag). Reconnect 12V battery negative terminal. Using Rivian diagnostic scan tool, register new battery module to vehicle BMS - enter module serial number and follow BMS learning procedure. Allow BMS to perform module balancing and integration routine (may take 30-60 minutes). Verify no DTC codes present. Perform isolation resistance test through scan tool - must show minimum 500 ohms/volt isolation. Command HV system to active mode. Verify pack voltage is within expected range (check individual module voltages are balanced within 0.1V). Perform final system verification and clear service mode.

Reassembly

1. Verify all HV connections are properly torqued and secured with cover plates
2. Confirm all coolant connections are leak-free and properly locked
3. Ensure BMS wiring harness is properly routed and secured with cable ties
4. Verify battery thermal management system is properly filled and bled of air
5. Confirm all underbody aero panels are reinstalled with proper fasteners
6. Remove high voltage safety equipment and store properly
7. Generate service report documenting module serial numbers, torque values, and BMS commissioning results

Verification

• Using scan tool, verify new battery module is recognized by BMS and reports correct serial number
• Check that all module voltages are within 0.1V of each other indicating proper balance
• Verify pack isolation resistance test shows minimum 500 ohms/volt to chassis ground
• Confirm battery thermal management system maintains proper temperature range (typically 20-35°C at rest)
• Test drive vehicle in controlled environment - monitor for any HV system warnings or reduced power messages
• Perform regenerative braking test to verify module can accept charge properly
• Using scan tool, verify no stored or pending DTCs related to HV battery system
• Check coolant level after test drive and top off if needed - recheck for leaks at all connection points
• Document final module voltages, temperatures, and system health status in service records
• Advise customer that BMS may continue learning new module characteristics for 50-100 miles of driving

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