Regenerative Braking Calibration

This procedure calibrates the regenerative braking system on the 2025 Rivian EDV 500 to ensure proper energy recovery and braking balance between regenerative and friction braking systems.

Warnings

Tools required

Fluids

• DOT 4 Brake Fluid

Preparation

1. Park vehicle on level ground and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Verify 12V auxiliary battery is fully charged (12.6V or higher at rest)
4. Connect battery maintainer to 12V auxiliary battery to prevent voltage drop during calibration
5. Verify high-voltage battery state of charge is between 40-80% for optimal calibration
6. Check brake fluid reservoir level - top off with DOT 4 if below MIN mark
7. Ensure tire pressures are set to manufacturer specification (affects ABS/regen calibration)
8. Close all doors, hood, and liftgate to prevent interruption during automated tests

Procedure

1. 1

   Connect Diagnostic Equipment
   Connect the J2534 adapter cable to the OBD-II port located below the driver side dashboard. Launch Rivian Diagnostic Software on the laptop and establish communication with all vehicle modules. Verify communication with Battery Management System (BMS), Motor Control Units (Front and Rear), Brake Control Module (BCM), and Vehicle Control Unit (VCU).
2. 2

   Retrieve Pre-Calibration Fault Codes
   Scan all modules for Diagnostic Trouble Codes (DTCs). Document any existing codes related to braking system, motor controllers, or battery management. Address any critical faults (hard codes) before proceeding. Soft codes related to regen calibration mismatch are expected and will be cleared after calibration.
3. 3

   Verify System Readiness
   Navigate to Service Functions > Regenerative Braking > System Status. Verify the following conditions are met: Brake fluid level OK, Motor temperatures below 140°F, Battery temperature between 50-95°F, No active traction control events, ABS system functional. If any condition fails, address before continuing.
4. 4

   Perform Brake Pedal Position Sensor Calibration
   Select Service Functions > Brake Pedal Calibration. Follow on-screen prompts to calibrate pedal position sensor. With vehicle in Park and powered on (not READY mode), press and hold brake pedal at full travel for 5 seconds. Release pedal completely and allow to return to rest position. Software will capture zero point and full travel positions. Confirm calibration acceptance on screen.
5. 5

   Initialize Regenerative Braking Calibration
   Navigate to Service Functions > Regenerative Braking > Calibration Wizard. Select 'Begin New Calibration' and confirm vehicle configuration (EDV 500, Dual Motor AWD). The system will perform an automatic pre-check of all relevant sensors and actuators. Wait for green confirmation before proceeding to next screen.
6. 6

   Perform Stationary Motor Torque Baseline
   With vehicle still in Park, select 'Motor Torque Baseline Test'. The system will command each motor individually to verify torque sensor accuracy and response time. You will hear slight whirring from each motor as they perform micro-rotation tests. This takes approximately 2-3 minutes. Do not touch brake or accelerator pedals during this test.
7. 7

   Execute Rolling Calibration - Phase 1
   Following software prompts, prepare for test drive. Put vehicle in Drive mode and proceed to a safe, level road with minimal traffic. Accelerate smoothly to 30 mph and release accelerator pedal completely without touching brake. Allow vehicle to coast and experience regenerative braking deceleration. Software will monitor regen current, motor torque, and deceleration rate. Repeat this cycle 5 times as prompted by software.
8. 8

   Execute Rolling Calibration - Phase 2
   Continue test drive per software instructions. Accelerate to 45 mph and perform moderate braking (approximately 30% pedal travel) to slow to 20 mph. The system is learning the blend point between regenerative and friction braking. Perform this cycle 8 times as directed, maintaining consistent pedal application rates. Software will provide real-time feedback on calibration quality.
9. 9

   Execute Rolling Calibration - Phase 3
   Final calibration phase requires firmer braking events. Accelerate to 50 mph and perform moderate-to-firm braking (50-60% pedal travel) to complete stop. This calibrates the transition to full friction braking and ABS integration points. Repeat 6 times as prompted. Ensure each stop is smooth and controlled without triggering ABS.
10. 10

    Complete Regenerative Paddle Calibration
    Return to low-speed area (under 35 mph). Use the steering wheel-mounted regenerative paddle to test maximum regen mode. Accelerate to 30 mph, release accelerator, and pull/hold regenerative paddle to maximum position. Allow vehicle to decelerate to 5 mph using only regen paddle. Repeat 4 times. Software calibrates maximum single-pedal driving regeneration rates.
11. 11

    Return and Finalize Calibration
    Return vehicle to starting location and place in Park. Software will perform final calculations and write calibration values to motor controllers and brake control module. This process takes 3-5 minutes. Do not power off vehicle or disconnect diagnostic equipment during this phase. Wait for 'Calibration Complete' confirmation message.
12. 12

    Verify Calibration Data
    Review calibration results in diagnostic software. Verify that front motor regen torque curve, rear motor regen torque curve, and brake blend map all show 'PASS' status. Check that calibration confidence level is 95% or higher. If below 95%, software will indicate which phase needs to be repeated.
13. 13

    Clear Calibration Fault Codes
    Navigate to Fault Codes section and clear all regen-related soft codes that were present before calibration. Re-scan system to verify no new codes have been set. Document final system status and any remaining codes (unrelated to regen system).

Reassembly

1. Disconnect diagnostic equipment from OBD-II port
2. Remove battery maintainer if used
3. Remove wheel chocks
4. Verify all vehicle warning lights are normal after cycling power off and on

Verification

• Perform test drive and verify smooth regenerative braking engagement when releasing accelerator pedal
• Confirm no harsh transitions between regenerative and friction braking during moderate stops
• Test regenerative paddle function - should provide progressively stronger deceleration
• Verify brake pedal feel is consistent with no sponginess or excessive travel
• Monitor regenerative power flow on driver display during coasting - should show consistent kW regeneration appropriate to speed and deceleration rate
• Confirm no new brake system or motor controller warning lights are present
• Verify regenerative braking energy recovery percentage is within normal range (typically 65-85% depending on driving conditions)
• Test emergency braking - ABS should engage normally without regenerative system interference

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