This procedure covers the replacement of the Level 2 charging cable assembly on the 2023 Rivian EDV 500, including removal of interior trim panels and electrical connections.

Warnings

Tools required

Parts

• Level 2 charging cable assembly × 1 — Use OEM specification
• Cable retaining clips × 4 — Use OEM specification
• Charge port trim panel clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off vehicle completely using main power button
3. Wait 5 minutes for high voltage system to de-energize
4. Disconnect 12V battery negative terminal and wait additional 2 minutes
5. Open charge port door and verify no charging cable is connected
6. Take photos of existing cable routing before removal for reference during installation

Procedure

1. 1

   Remove charge port trim panel
   Using plastic trim tools, carefully pry the charge port trim panel from the exterior body panel. Start at the bottom edge and work around the perimeter. Release the retaining clips and disconnect any ambient lighting connectors if equipped. Set panel aside in safe location to prevent scratching.
2. 2

   Access charging cable mounting point
   Remove the T25 Torx screws securing the charge port mounting bracket to the body structure. There are typically 4 screws around the perimeter. Carefully pull the charge port assembly forward approximately 3-4 inches to access the cable connections behind.
3. 3

   Disconnect charge port electrical connectors
   Locate the main charging cable connector at the rear of the charge port assembly. Press the locking tab and carefully pull the connector straight back to disconnect. Note the orientation and any locking mechanisms. Disconnect the secondary ground wire connection using a 10mm socket.
4. 4

   Remove cargo area trim panels
   From inside the cargo area, remove the driver side rear trim panel using plastic trim tools. Release all retaining clips working from top to bottom. This provides access to the cable routing path from charge port to onboard charger location.
5. 5

   Release cable retaining clips
   Locate and release all cable retaining clips along the routing path. These clips secure the charging cable to the body structure. Typically 4-6 clips are present along the route. Press the release tabs and slide the cable out of each clip. Document clip locations for reassembly.
6. 6

   Access onboard charger connections
   Locate the onboard charger module in the rear cargo area (typically driver side). Remove the T30 Torx screws securing the charger cover. There are usually 6 screws around the perimeter. Carefully remove the cover to expose the charging cable connections.
7. 7

   Disconnect charging cable from onboard charger
   Identify the Level 2 charging cable connections to the onboard charger. Press the connector locking tabs and pull straight out to disconnect both AC line connections. Note the color coding and orientation of connectors (typically labeled L1 and L2). Remove the ground connection using a 10mm socket.
8. 8

   Remove old charging cable
   Carefully pull the charging cable from the charge port end while feeding it through all body cavities and grommets. Work slowly to avoid damaging other wiring harnesses or components. Remove any remaining cable ties or clips securing the cable to adjacent harnesses.
9. 9

   Route new charging cable
   Starting from the onboard charger end, route the new Level 2 charging cable through the same path as the original. Use cable routing tools or fish tape if necessary to guide cable through tight spaces and body cavities. Ensure cable passes through all original grommets and routing holes to maintain water and dust sealing.
10. 10

    Connect cable to onboard charger
    Connect the new charging cable to the onboard charger, matching the L1 and L2 designations. Push connectors firmly until locking tabs engage with an audible click. Reconnect ground wire and tighten 10mm bolt securely. Verify all connections are fully seated and locked.
11. 11

    Secure cable routing
    Install new or reuse existing cable retaining clips at all documented locations along the cable path. Ensure cable has appropriate slack and is not stretched tight or routed near any sharp edges. Cable should follow natural contours and not contact any moving components or high-heat areas.
12. 12

    Connect cable to charge port
    Feed the charge port end of the cable through the body opening. Connect the main connector to the charge port assembly, ensuring proper alignment and locking tab engagement. Reconnect ground wire using 10mm socket. Verify connection is secure and properly oriented.
13. 13

    Reinstall charge port assembly
    Push the charge port assembly back into its original position in the body panel opening. Align all mounting holes and install T25 Torx screws around the perimeter. Ensure charge port sits flush with body panel and operates smoothly when opening and closing.

Reassembly

1. Reinstall onboard charger cover with all T30 Torx screws
2. Reinstall cargo area trim panel, ensuring all retaining clips are fully engaged
3. Reconnect any ambient lighting connectors to charge port trim panel
4. Reinstall charge port exterior trim panel, pressing firmly to engage all clips
5. Reconnect 12V battery negative terminal
6. Verify charge port door operates correctly and closes flush

Verification

• Power on the vehicle and check for any charging system error messages on the instrument cluster
• Access vehicle settings and verify Level 2 charging functionality is recognized
• Connect a Level 2 charging cable to the charge port and verify vehicle begins charging cycle
• Monitor charging for at least 5 minutes to ensure stable connection and no errors
• Check that charging rate displays correctly on instrument cluster
• Verify no unusual sounds or heat at charge port or cable connections
• Inspect all reinstalled trim panels for proper fit and secure attachment
• Test charge port door operation multiple times to ensure smooth function

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