Comprehensive state safety inspection of a 2025 Rivian EDV 500 commercial electric delivery van, covering all required systems including brakes, lights, steering, suspension, and electrical components.

Warnings

Tools required

Preparation

1. Verify vehicle registration and VIN match inspection request
2. Ensure battery has sufficient charge (minimum 30%) to complete all system tests
3. Position vehicle on level surface with adequate lighting
4. Place wheel chocks behind rear wheels
5. Have state inspection form or digital inspection system ready
6. Review any customer complaints or known issues prior to inspection

Procedure

1. 1

   Interior and Driver Controls Inspection
   With vehicle powered on, check operation of horn, windshield wipers (all speeds), washer fluid spray pattern, and parking brake function. Verify all required mirrors are present and adjustable. Check driver's seat belt for proper latching, retraction, and condition. Inspect all interior lighting including dome lights and cargo area lights. Verify operation of turn signal indicators on instrument cluster.
2. 2

   Instrument Cluster and Warning Light Check
   Power on vehicle to RUN mode without engaging drivetrain. Verify all warning lights illuminate during self-test, then extinguish. Confirm no active dashboard warning lights remain on, particularly ABS, traction control, airbag, high-voltage system, or brake warnings. Note odometer reading on inspection form.
3. 3

   Exterior Lighting Inspection
   Test all exterior lights: headlights (low and high beam), front and rear turn signals, brake lights, tail lights, reverse lights, license plate light, and any required clearance or marker lights for commercial vehicle classification. Verify amber side marker lights on EDV 500 commercial body. Check for proper lens condition with no cracks or missing lenses. Use headlight aim gauge to verify proper headlight alignment per state requirements.
4. 4

   Windshield and Glass Inspection
   Inspect windshield for cracks, chips, or damage in driver's field of vision. Check that no damage extends into critical vision area (typically measured from wiper sweep area). Inspect all windows for proper operation and condition. Verify rear visibility through mirrors or backup camera system is adequate for commercial delivery use.
5. 5

   Tire Inspection
   Inspect all tires including spare if equipped. Measure tread depth at multiple points across each tire; minimum tread depth must meet state requirements (typically 2/32" for passenger vehicles, 4/32" for commercial vehicles - verify local requirements for EDV classification). Check for uneven wear, sidewall damage, bulges, or exposed cords. Verify all tires are same size and type per manufacturer specifications. Check tire pressure against door placard specification and adjust as needed.
6. 6

   Wheel and Lug Nut Inspection
   Visually inspect all wheels for cracks, bends, or damage. Check all lug nuts are present and properly seated. Look for signs of looseness such as rust streaks or movement patterns around lug nuts. For commercial vehicle inspection, verify wheel rating is appropriate for vehicle GVWR.
7. 7

   Brake System Performance Test
   Perform brake pedal effort test. With vehicle running, apply brakes firmly and verify solid pedal feel with no excessive travel or sinking. Pedal should not go more than halfway to floor under firm pressure. Test parking brake holding ability on a grade if possible, or verify it holds vehicle stationary when released from wheel chocks. Check brake fluid level in reservoir; should be between MIN and MAX marks. Fluid should be clear amber, not dark or contaminated.
8. 8

   Undercarriage Inspection - Front Suspension and Steering
   Raise vehicle using approved lift points per Rivian service manual. Safely support on jack stands. Inspect front suspension components including control arms, ball joints, tie rod ends, and steering rack boots for wear, damage, or excessive play. Check CV axle boots for tears or grease leakage. Grasp each front wheel at 12 and 6 o'clock positions and check for vertical play indicating ball joint or wheel bearing wear. Grasp at 3 and 9 o'clock and check for lateral play indicating tie rod or steering component wear.
9. 9

   Undercarriage Inspection - Rear Suspension
   Inspect rear suspension components including control arms, trailing arms, shocks or air springs, and bushings for wear, damage, or leakage. Check for any signs of collision damage or improper repairs. Verify rear differential mounts are secure with no excessive play. Inspect rear CV axle boots for damage or leakage.
10. 10

    Brake Component Inspection
    Inspect brake rotors through wheel spokes or with wheels removed. Check for minimum thickness, scoring, cracking, or excessive rust. Measure rotor thickness at multiple points and compare to minimum specification. Inspect brake pads through caliper inspection window or directly; minimum pad thickness typically 3mm or per state requirement. Check for uneven pad wear. Inspect brake lines and hoses for damage, leaks, chafing, or deterioration. Verify no fluid leaks at calipers or connections.
11. 11

    Battery Pack and Underbody Inspection
    Visually inspect high-voltage battery pack enclosure for any damage, dents, or signs of impact. Check for any fluid leaks from battery coolant system (orange/pink coolant). Inspect underbody panels and skid plates for damage or missing fasteners. Verify no components are hanging loose or improperly secured. Check exhaust system is secure (if equipped with cabin heater combustion system).
12. 12

    Frame and Body Integrity Check
    Inspect frame rails and unibody structure for rust, damage, or evidence of collision repair. Check all body mounting points are secure. For commercial EDV body, verify cargo area floor and walls show no structural damage or excessive wear that could compromise load capacity. Inspect door hinges and latches for proper operation and alignment.
13. 13

    Diagnostic System Scan
    Connect OBD-II scanner to diagnostic port. Retrieve any stored diagnostic trouble codes (DTCs) from all vehicle modules including powertrain, ABS, airbag, and body control systems. Record all codes. Check for pending codes or history codes that might indicate intermittent issues. Verify readiness monitors are set (note: EVs may have fewer monitors than traditional vehicles). Clear codes only if confirmed to be false or resolved issues; active codes typically result in inspection failure.
14. 14

    Road Test and Final Verification
    Perform road test in safe area. Verify steering operates smoothly with no binding, excessive play, or pulling. Test service brakes at various speeds; vehicle should stop straight without pulling, and ABS should be functional (if equipped with ABS test mode, activate it). Check for any unusual noises, vibrations, or handling issues. Test regenerative braking system operates normally. Verify all drive modes function properly. Return to shop and lower vehicle from jack stands if still raised.

Reassembly

1. Lower vehicle safely from jack stands if raised
2. Remove wheel chocks and return tools to storage
3. Verify all inspection points have been documented on state inspection form

Verification

• Review completed inspection form for all required checkpoints
• Verify no warning lights are illuminated on instrument cluster
• Confirm all tested systems operate within acceptable parameters per state requirements
• If inspection passed, affix state inspection sticker per local regulations
• If inspection failed, provide customer with detailed list of deficiencies requiring repair
• Document odometer reading and inspection results in vehicle service records

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