This procedure covers the removal and replacement of the Level 2 charging cable assembly on a 2022 Rivian EDV 500 delivery van.

Warnings

Tools required

Parts

• Level 2 charging cable assembly × 1 — Use OEM specification
• Cable retention clips × 1 — Use OEM specification
• Charge port seal/gasket × 1 — Use OEM specification
• Cable harness zip ties × 1 — UV-resistant automotive grade

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is fully powered off using center console power button
3. Verify charging cable is disconnected from any external charging source
4. Open rear cargo area and access panels for cable routing path
5. Put on insulated high-voltage gloves and safety equipment
6. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
7. Access HV disconnect service panel and verify lockout/tagout procedures
8. Document cable routing path with photos before removal

Procedure

1. 1

   Access charging port assembly
   Remove the driver side front fender trim panel to access the Level 2 charging port. Remove the Torx screws securing the charge port access panel. Carefully pull the panel away from the body using trim tools to release the retention clips.
2. 2

   Disconnect charge port electrical connector
   Locate the main charging port connector behind the access panel. Press the connector lock tab and carefully disconnect the charge port status harness connector. This is a gray 12-pin connector located at the top of the charge port assembly.
3. 3

   Remove charge port mounting hardware
   Remove the four mounting bolts securing the charge port housing to the body. Support the charge port assembly while removing the final bolt to prevent it from falling. Note the position of any grounding straps or brackets.
4. 4

   Disconnect cable from onboard charger
   Access the front power electronics bay on the passenger side. Locate the onboard charger module with orange high-voltage cable connections. Remove the protective covers from the HV cable terminals. Remove the HV cable retention bolts and carefully separate the cable lugs from the charger input terminals.
5. 5

   Release cable routing clips
   Working from the charge port toward the onboard charger, locate and release all cable retention clips along the frame rail and inner fender. There are approximately 8-12 clips securing the cable path. Cut and remove all zip ties securing the cable bundle to other harnesses.
6. 6

   Remove cable through body passage
   Carefully pull the charging cable through the body passage from the charge port area toward the power electronics bay. Work slowly to avoid snagging on sharp edges. If resistance is felt, check for missed retention points. The cable should pass through a protective grommet in the firewall area.
7. 7

   Inspect mounting locations
   With the old cable removed, inspect all mounting points, grommets, and cable passage areas for damage, corrosion, or wear. Clean mounting surfaces and replace the charge port seal/gasket. Verify no debris is present in cable routing channels.
8. 8

   Route new charging cable
   Begin routing the new Level 2 charging cable from the onboard charger end through the body passage toward the charge port location. Follow the documented cable path from preparation photos. Apply cable routing lubricant to grommets if needed. Ensure cable is not twisted or kinked during installation.
9. 9

   Connect cable to onboard charger
   Position the HV cable lugs onto the onboard charger input terminals, ensuring proper orientation and full seating. Install the HV cable retention bolts and tighten evenly. Verify connections are fully seated and install protective covers over HV terminals. Confirm no gaps or misalignment at connections.
10. 10

    Secure cable routing
    Install new cable retention clips at all factory locations along the frame rail and inner fender. Ensure cable has proper service loop at both ends and is not under tension. Secure cable bundle to existing harnesses using new UV-resistant zip ties, maintaining minimum 2-inch spacing from heat sources.
11. 11

    Install charge port assembly
    Position the charge port housing with new seal/gasket into the body opening. Install the four mounting bolts and tighten in a cross pattern. Reconnect the charge port status harness connector, ensuring positive lock engagement. Verify charge port door opens and closes smoothly.
12. 12

    Reinstall access panels
    Reinstall the charge port access panel, ensuring all retention clips engage properly. Install and tighten all Torx screws. Reinstall the driver side front fender trim panel. Verify all panels are flush and properly secured.
13. 13

    Restore vehicle power systems
    Remove lockout/tagout devices from HV disconnect. Reconnect the 12V auxiliary battery negative terminal. Power on the vehicle using the center console button. Monitor the instrument cluster for any fault codes or warning messages related to charging system.

Reassembly

1. Verify all access panels and trim pieces are properly secured and aligned
2. Confirm no tools or parts were left in the work areas
3. Ensure all cable retention clips and zip ties are properly installed
4. Double-check HV connections are covered and protected

Verification

• Connect a known-good Level 2 EVSE to the charge port and verify charging initiates properly
• Confirm charge port status light illuminates correctly when cable is inserted
• Use vehicle display to verify charging current and voltage readings are within normal parameters
• Check for any fault codes using Rivian diagnostic system
• Perform visual inspection of entire cable route to confirm no interference or contact with moving parts
• Verify charge port door operation and sealing
• Test charge with vehicle both on and in sleep mode to confirm proper operation
• Monitor first charging session for any unusual noises, smells, or heat at connections

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