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2023 RIVIAN EDV 500
Dual Motor AWD (EDV)•FWD•ev
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Repairs276Labor323Torque97Fluid6DTC726Battery1Maintenance0Recalls0
ev-charging

Onboard Charger R&R

for 2023 Rivian EDV 500 Dual Motor AWD (EDV) · FWD
Editorial review:Chris Hackleman — Master Technician · 20+ years
Difficulty
Expert
Time
3.0 h
Tools
11
Steps
15
✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman — 20+ years each). Always follow the vehicle's factory service information and torque specs.

Remove and replace the onboard charger assembly on a 2023 Rivian EDV 500, including high voltage disconnection, coolant system drainage, and electrical harness removal.

Warnings

⚠️High voltage system present. Failure to properly disconnect and verify de-energization can result in severe injury or death. Only qualified technicians with HV certification should perform this procedure.
⚠️Wait minimum 15 minutes after HV disconnect before touching any high voltage components to allow capacitors to discharge.
⚠EV coolant may be hot even when vehicle has been off. Allow cooling system to cool completely before draining.
⚠The onboard charger weighs approximately 35 lbs. Use proper lifting technique or assistance.
ℹ️Document all connector positions and routing with photos before disconnection for proper reassembly.

Tools required

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Fluids

  • EV Battery/Motor Coolant — 3 qt

Preparation

  1. Park vehicle on level surface and engage parking brake
  2. Ensure vehicle is powered off and key fob is at least 15 feet away from vehicle
  3. Access Rivian service mode through diagnostic tool to place HV system in safe service state
  4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
  5. Raise front of vehicle and secure on jack stands rated for vehicle weight
  6. Remove front underbody panel to access HV components and charger assembly
  7. Place coolant drain pan beneath charger area
  8. Allow vehicle to sit for minimum 15 minutes after HV disconnect

Procedure

  1. 1
    Verify high voltage system de-energization
    Put on high voltage insulated gloves. Using HV safety meter, verify voltage at HV battery disconnect point reads 0V DC. Check multiple HV connection points to confirm system is fully discharged. Document voltage readings.
  2. 2
    Disconnect HV service disconnect
    Locate HV service disconnect under front cargo area. Remove service disconnect cover. Pull HV service disconnect plug straight out and store in a secure location away from vehicle. Install service cover over exposed contacts. Lock out/tag out the disconnect location.
  3. 3
    Drain coolant from charger circuit
    Locate coolant drain valve on charger inlet line. Attach drain hose to valve and route to drain pan. Open drain valve and allow coolant to drain completely from charger circuit. Close valve when drainage stops. Remove coolant hoses from charger by releasing spring clamps and pulling hoses straight off ports.
  4. 4
    Disconnect low voltage harness
    Locate low voltage control connector on front side of charger assembly. Press release tab and disconnect connector. Remove connector from mounting bracket. Label connector orientation for reinstallation.
  5. 5
    Disconnect AC input harness
    Locate AC input harness connection at rear of charger assembly. Remove protective cover from AC connector. Press connector lock release and carefully disconnect AC power connector. Secure connector away from work area with zip tie or tape.
  6. 6
    Disconnect DC output cables
    Remove protective covers from DC output terminals on charger. Remove DC cable retaining bolts using appropriate socket. Carefully lift DC cables away from charger terminals. Cover exposed terminals with insulating material. Label cable positions for correct reinstallation.
  7. 7
    Remove charger mounting fasteners
    Locate charger assembly mounting bolts (typically 4-6 bolts securing charger to mounting bracket). Remove all mounting bolts using Torx or socket as appropriate. Support weight of charger while removing final bolt. Note location of any ground straps or brackets that must be reinstalled.
  8. 8
    Remove charger assembly
    With assistance or proper lifting equipment, carefully lower charger assembly from mounting location. Maneuver charger through access area, being careful not to damage surrounding components or harnesses. Place charger on clean work surface. Inspect mounting area and coolant ports for debris or damage.
  9. 9
    Prepare new charger for installation
    Unpack new charger assembly and verify part number matches application. Install new gasket/seal onto charger mounting surface. Verify all coolant ports have proper O-rings installed. Remove any shipping plugs or protective covers from electrical connections.
  10. 10
    Install new charger assembly
    With assistance, lift new charger into mounting position, aligning mounting holes and ensuring no harnesses or hoses are pinched. Install mounting bolts hand-tight, ensuring proper alignment. Torque mounting bolts in star pattern to manufacturer specification (record values for documentation).
  11. 11
    Reconnect DC output cables
    Remove insulating material from DC terminals. Align DC output cables to correct terminals per labels. Install and hand-tighten DC cable retaining bolts. Torque DC terminal bolts to manufacturer specification (record values). Install protective covers over DC connections.
  12. 12
    Reconnect AC input and low voltage harnesses
    Connect AC input harness to charger, ensuring connector is fully seated and lock engages. Install AC connector protective cover. Connect low voltage control connector, ensuring proper alignment and secure lock engagement. Verify connector is properly secured in mounting bracket.
  13. 13
    Refill coolant system
    Install new hose clamps on coolant hoses. Reconnect coolant hoses to charger inlet and outlet ports, ensuring hoses are fully seated. Tighten clamps securely. Fill coolant system with EV Battery/Motor Coolant through designated fill point. Use vacuum fill tool if available to ensure proper fill and no air pockets. Fill to proper level and install fill cap.
  14. 14
    Reinstall HV service disconnect and verify connections
    Perform final visual inspection of all connections, mounting bolts, and coolant hoses. Remove service cover from HV disconnect location. Reinstall HV service disconnect plug, ensuring it is fully seated and locked. Reinstall disconnect cover. Double-check all HV connections are secure and properly insulated.
  15. 15
    Complete system initialization
    Reconnect 12V auxiliary battery negative terminal. Using diagnostic tool, clear service mode and perform onboard charger initialization procedure. Check for any fault codes. Clear any installation-related codes. Verify charger communication with vehicle control systems.

Reassembly

  1. Reinstall front underbody panel and torque fasteners per specification
  2. Lower vehicle from jack stands
  3. Check coolant level after system has circulated and top off if necessary
  4. Verify no coolant leaks around charger connections
  5. Ensure all HV protective covers are installed and secure

Verification

  • Connect vehicle to AC charging station and verify charger begins charging cycle
  • Monitor charging session for minimum 10 minutes to confirm stable operation
  • Check for any abnormal sounds, smells, or heat from charger area during charging
  • Verify charging rate matches expected values for AC input type
  • Using diagnostic tool, confirm no fault codes related to onboard charger
  • Verify coolant level remains stable after charging session
  • Inspect all connections for coolant leaks after charging cycle
  • Perform test drive and verify all vehicle systems operate normally
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