Onboard Charger R&R

This procedure covers the removal and replacement of the onboard charger module on a 2022 Rivian EDV 500 electric delivery vehicle with dual motor all-wheel drive.

Warnings

Tools required

Parts

• Onboard charger assembly × 1 — Use OEM specification
• Coolant hose O-rings × 2 — Use OEM specification
• HV connector seals (if damaged) × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off for at least 30 minutes and high voltage system is cool
3. Disconnect 12V auxiliary battery negative terminal
4. Access Rivian service mode through vehicle interface or diagnostic tool to disable high voltage system
5. Verify service mode is active (dashboard will display HV DISABLED message)
6. Remove front underbody panels to access onboard charger location in front compartment area
7. Allow high voltage capacitors to discharge for minimum 15 minutes after service mode activation

Procedure

1. 1

   Verify high voltage isolation
   Using a properly rated high voltage multimeter, verify that no voltage is present between HV+ and HV- terminals at the onboard charger. Also verify no voltage between HV terminals and vehicle chassis ground. Reading should be 0V DC. Do not proceed if any voltage is detected.
2. 2

   Drain coolant from charger circuit
   Locate the coolant drain valve on the charger cooling circuit. Place a suitable drain pan underneath. Open the drain valve and allow approximately 1 quart of EV coolant to drain from the charger circuit. Close drain valve when flow stops.
3. 3

   Disconnect charge port wiring harness
   Locate the charge port communication harness connector on the onboard charger. Press the release tab and disconnect the connector. Secure the harness away from the work area.
4. 4

   Disconnect AC input connector
   While wearing high voltage insulated gloves, locate the AC input connector from the charge port. This is typically a large orange connector. Pull back the orange safety lock, then press the release mechanism and carefully disconnect the AC input connector from the onboard charger.
5. 5

   Disconnect high voltage DC output connector
   Locate the high voltage DC output connector (orange cable) going to the battery pack. Pull back the orange safety interlock, then depress the connector release mechanism. Carefully pull the connector straight out from the onboard charger module. Cover exposed terminals with electrical tape.
6. 6

   Disconnect coolant lines
   Using a 10mm socket, loosen the coolant line clamps or quick-disconnect fittings at the inlet and outlet ports of the onboard charger. Have a drain pan ready to catch residual coolant. Disconnect both coolant lines and plug the lines with suitable caps to prevent contamination.
7. 7

   Remove charger mounting fasteners
   Locate the mounting bolts securing the onboard charger to its bracket. There are typically 4-6 mounting bolts. Using appropriate sockets (13mm or T30 Torx depending on fastener type), remove all mounting bolts. Keep fasteners organized for reinstallation.
8. 8

   Remove onboard charger assembly
   Carefully slide the onboard charger forward and out of its mounting bracket. The unit weighs approximately 35 lbs, so maintain proper grip and use assistance if needed. Remove the charger from the vehicle and place on a clean work surface.
9. 9

   Inspect mounting area and connections
   Inspect the mounting bracket for damage or corrosion. Check all electrical connectors for damage, corrosion, or bent pins. Inspect coolant line O-rings and replace if worn, cracked, or flattened. Clean mounting surfaces with a wire brush if needed.
10. 10

    Install replacement onboard charger
    Position the new onboard charger into the mounting bracket, aligning it with the mounting holes. Install all mounting bolts finger-tight first to ensure proper alignment. Then torque mounting bolts in a cross-pattern to proper specification per service manual.
11. 11

    Reconnect coolant lines
    Install new O-rings on coolant line fittings if applicable. Connect coolant inlet and outlet lines to the onboard charger, ensuring proper seating. Secure with clamps or quick-disconnect fittings, tightening to proper specification.
12. 12

    Reconnect high voltage DC output
    Remove tape from DC output terminals. Apply a thin layer of dielectric grease to connector if specified. Align the DC output connector and push firmly until it clicks into place. Engage the orange safety interlock. Verify connector is fully seated.
13. 13

    Reconnect AC input connector
    Align and connect the AC input connector from the charge port to the onboard charger. Push firmly until it clicks into place. Engage the orange safety lock. Tug gently to verify secure connection.
14. 14

    Reconnect communication harness and refill coolant
    Reconnect the charge port communication harness to the onboard charger until it clicks. Refill the charger cooling circuit with fresh EV Battery/Motor Coolant through the fill port. Add approximately 1 quart or until level is correct. Bleed air from cooling system per manufacturer procedure.
15. 15

    Exit service mode and test
    Reinstall front underbody panels. Reconnect 12V auxiliary battery. Exit service mode through vehicle interface or diagnostic tool. Start vehicle and verify no HV system faults are present. Perform charging system test to verify proper operation.

Reassembly

1. Ensure all high voltage connectors are properly locked with safety interlocks engaged
2. Verify coolant system is properly filled and bled of air
3. Check for coolant leaks around charger connections before closing panels
4. Reinstall all underbody panels and fasteners removed during access
5. Clear any service mode codes and restore vehicle to normal operation

Verification

• Start vehicle and verify no high voltage warning lights or fault codes are present
• Connect vehicle to charging station and verify charging initiates normally
• Monitor charging for at least 15 minutes to ensure proper operation and no thermal issues
• Check for coolant leaks around onboard charger connections
• Verify charge rate matches expected performance for the charging source
• Test drive vehicle briefly and recheck for any warning lights or fault codes

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