Inverter R&R

Complete removal and replacement of the power inverter assembly on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, including high voltage system isolation, coolant draining, and electrical disconnection.

Warnings

Tools required

Parts

• Power inverter assembly × 1 — Use OEM specification
• Inverter coolant inlet O-ring × 1 — Use OEM specification
• Inverter coolant outlet O-ring × 1 — Use OEM specification
• High voltage connector seals (if damaged) × 2 — Use OEM specification
• Inverter mounting hardware kit × 1 — Use OEM specification
• Thermal interface compound × 1 — Rivian specified thermal compound

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Ensure vehicle is parked on level ground with parking brake engaged and wheels chocked
2. Verify ignition is OFF and key fob is at least 15 feet away from vehicle
3. Connect Rivian diagnostic tool and document any existing fault codes
4. Place high voltage warning signs on vehicle and implement lockout/tagout procedures
5. Don high voltage safety gloves and protective equipment
6. Open rear cargo doors and remove any cargo or interior panels blocking access to inverter compartment (typically located under vehicle chassis)
7. Raise vehicle on lift to access undercarriage inverter mounting location
8. Allow inverter and coolant system to cool to ambient temperature (minimum 2 hours after last operation)

Procedure

1. 1

   Disable high voltage system
   Locate the high voltage disconnect (typically in front trunk area). Open service disconnect cover and remove the service disconnect plug by rotating counterclockwise and pulling straight out. Store disconnect plug in a secure location away from vehicle. Install lockout device on service disconnect receptacle and attach LOTO tag with technician information.
2. 2

   Verify high voltage isolation
   Wait minimum 15 minutes for high voltage capacitors to discharge. Using insulated high voltage multimeter, verify 0V DC at the inverter HV terminals. Test between positive and negative terminals, positive to chassis ground, and negative to chassis ground. Document all voltage readings as 0V before proceeding. Attach 'VERIFIED SAFE' tag to work area.
3. 3

   Drain inverter coolant circuit
   Locate the inverter coolant drain valve on the lower coolant line beneath the inverter assembly. Place drain pan underneath with minimum 12 quart capacity. Open drain valve and allow coolant to drain completely. If coolant is contaminated or discolored, flush circuit with fresh coolant before proceeding. Close drain valve after draining is complete.
4. 4

   Disconnect low voltage electrical connections
   Disconnect the 12V negative battery terminal to prevent accidental system activation. Locate and disconnect all low voltage connectors to the inverter: temperature sensors (2 connectors), resolver feedback connector, communication CAN bus connector, and ground straps. Label each connector with tape and marker for correct reassembly. Secure connectors away from work area.
5. 5

   Disconnect coolant lines
   Using appropriate wrench, loosen the coolant inlet and outlet line fittings at the inverter. Expect residual coolant drainage (approximately 0.5-1.0 quart). Remove coolant lines and immediately cap open ports with protective plugs to prevent contamination. Inspect O-rings on coolant line ends and inverter ports for damage. Replace if cut, torn, or flattened.
6. 6

   Remove high voltage DC input connector
   Wearing insulated HV gloves, locate the high voltage DC input connector from battery pack on the front side of inverter. Pull back the orange connector locking tab. Depress the secondary lock release mechanism and carefully pull connector straight away from inverter. Do not twist or rock connector. Immediately install protective cover over exposed inverter HV terminals. Inspect connector pins for damage, corrosion, or discoloration.
7. 7

   Remove high voltage AC output connectors
   Locate the two or three-phase AC output connectors leading to front and rear drive motors. For each connector: pull back orange locking collar, release secondary lock, and pull connector straight out from inverter terminals. Install protective covers over all exposed HV terminals immediately. Inspect all AC connector pins and seals. Replace any damaged seals or connectors.
8. 8

   Support inverter assembly
   Position inverter lifting fixture or engine hoist under the inverter assembly. Attach lifting straps or hooks to designated lifting points on inverter housing (marked with lifting symbols). Take up slack in hoist to support inverter weight, but do not lift yet. Verify secure attachment and balanced support before proceeding.
9. 9

   Remove inverter mounting fasteners
   Locate all inverter mounting bolts (typically 4-6 bolts securing inverter to chassis mounting bracket). Remove mounting bolts in a cross pattern, loosening each bolt gradually to prevent binding. Keep all mounting hardware organized by location. Inspect mounting points on chassis for damage, corrosion, or cracks. Clean mounting surfaces with wire brush if necessary.
10. 10

    Remove inverter assembly from vehicle
    With lifting device supporting full weight of inverter, carefully lower and maneuver inverter assembly away from mounting bracket and vehicle chassis. Guide all cables and lines clear of inverter during removal. Lower inverter onto clean, padded work surface. Cover all exposed electrical terminals with protective caps. Place inverter in designated containment area if defective unit requires return to manufacturer.
11. 11

    Prepare new inverter for installation
    Unpack new inverter assembly and verify part number matches vehicle specification. Remove all protective shipping covers from electrical terminals. Inspect all terminals for shipping damage. Apply specified thermal interface compound to inverter mounting surface and heatsink interface areas per manufacturer specifications. Install new O-rings on coolant inlet and outlet ports, lubricating lightly with clean coolant.
12. 12

    Install new inverter assembly
    Using lifting device, carefully position new inverter assembly into mounting location, aligning mounting holes with chassis bracket. Guide inverter into position while ensuring no interference with coolant lines or electrical cables. Align all mounting holes before installing any fasteners. Insert all mounting bolts finger-tight initially.
13. 13

    Torque inverter mounting fasteners
    Torque all inverter mounting bolts in a cross pattern to ensure even clamping force and proper thermal contact. Since specific torque values are not available in the database, follow the torque specifications provided with the new inverter assembly or in the Rivian service manual for this chassis mounting application. Typical values for this application range from 35-50 ft-lbs, but use only verified specifications.
14. 14

    Reconnect high voltage connections
    Remove protective covers from inverter HV terminals. Inspect all HV connector pins for cleanliness and damage. Reconnect AC output connectors to front and rear motor phases first, ensuring connectors are fully seated with audible click. Engage secondary locks and orange locking collars. Then reconnect DC input connector from battery, ensuring full engagement, secondary lock engaged, and orange tab locked. Verify all HV connections are secure with no gaps visible.
15. 15

    Reconnect coolant lines and low voltage connections
    Reconnect coolant inlet and outlet lines to inverter, ensuring new O-rings are properly seated. Tighten coolant line fittings to manufacturer specification (typically 18-22 ft-lbs for this application, verify in service manual). Reconnect all low voltage electrical connectors in reverse order of removal, referencing labels applied during disassembly. Ensure all connector locks are fully engaged. Reconnect inverter ground straps. Reconnect 12V negative battery terminal.

Reassembly

1. Refill inverter coolant circuit with fresh EV Battery/Motor Coolant to specification (10 quarts total system capacity)
2. Bleed coolant system according to Rivian bleeding procedure to remove all air pockets
3. Reinstall any undercarriage panels or interior trim removed for access
4. Remove all lockout/tagout devices and warning signs from vehicle

Verification

• With diagnostic tool connected, reinstall high voltage service disconnect plug
• Perform inverter initialization and calibration procedure using Rivian factory diagnostic software
• Clear any fault codes generated during service
• Perform inverter self-test routine through diagnostic software and verify all systems pass
• Check for coolant leaks at all inverter connections with system pressurized
• Verify coolant level is correct after bleeding procedure
• Perform a controlled test drive at low speed (under 25 mph) in a safe area to verify proper motor operation
• Monitor inverter temperature during test drive using diagnostic tool - should remain within normal operating range (typically 40-85°C)
• Verify no fault codes present after test drive and proper operation of both front and rear drive motors
• Document all work performed including new inverter part number and software calibration data

More procedures for this vehicle