ev-charging

Charging Cable - Level 1

for 2024 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Moderate

Time

2.0 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure covers the removal and replacement of the Level 1 (120V) charging cable assembly on the 2024 Rivian EDV 500 commercial delivery van.

Warnings

⚠️The high-voltage charging system can deliver lethal voltage even when the vehicle is off. Always verify system is de-energized before beginning work.

⚠️Disconnect 12V auxiliary battery and wait 15 minutes before accessing high-voltage components to allow capacitors to discharge.

⚠EDV 500 commercial vehicles have different charging system routing than consumer R1T/R1S models. Do not reference consumer vehicle procedures.

⚠Handle charging cables carefully to avoid damaging conductor insulation or internal shielding.

Tools required

Trim panel removal tool setEssential

T20 Torx driverEssential

T30 Torx driverEssential

10mm socket and ratchetEssential

Cable tie removal tool

MultimeterEssential

Insulated gloves (Class 0)Essential

Vehicle lift or jack standsEssential

Work light

Parts

Level 1 charging cable assembly × 1 — Use OEM specification
Cable retention clips × 6 — Use OEM specification
Cable ties × 10 — UV-resistant automotive grade
Charging port seal × 1 — Use OEM specification

Preparation

Park vehicle on level surface and engage parking brake
Verify vehicle is powered off and key fob is at least 20 feet away
Open rear cargo doors and access 12V auxiliary battery compartment in left rear cargo area
Disconnect 12V auxiliary battery negative terminal and secure cable away from terminal
Wait minimum 15 minutes for high-voltage system capacitor discharge
Raise vehicle on lift or support securely on jack stands
Remove driver-side lower rocker panel trim to access cable routing channel

Procedure

1
Verify System De-energization
Using insulated gloves and multimeter set to DC voltage, verify no voltage present at charging port terminals. Access charging port by opening driver-side charging door. Measure voltage between positive and negative terminals - reading must be 0V DC. If voltage is present, do not proceed and investigate high-voltage system fault.
2
Remove Charging Port Cover Assembly
Open driver-side charging port door fully. Remove four T20 Torx screws securing inner port cover. Carefully pull cover forward to disengage two rear retention clips. Disconnect port light connector by pressing tab and pulling straight out. Set cover aside.
3
Disconnect Level 1 Cable from Charging Port
Locate Level 1 cable connector at charging port module (smaller connector, typically lower position). Press orange safety tab release and rotate counterclockwise 1/4 turn. Pull connector straight out from port module. Inspect connector pins for damage or corrosion.
4
Remove Cable Routing from Door Frame
Open driver door fully. Remove door sill trim plate by pulling up firmly to release clips. Locate cable routed through door frame channel behind B-pillar trim. Remove five cable retention clips by prying center pins up with trim tool, then pulling clips out. Carefully feed cable slack toward charging port area.
5
Access Underbody Cable Routing
From underneath vehicle, locate Level 1 cable routed along driver-side frame rail. Cut all cable ties securing cable to frame rail routing brackets using cable tie removal tool or flush cutters. Note cable routing path for reinstallation. Remove protective conduit sections by releasing snap clips.
6
Disconnect Cable at Onboard Charging Module
Locate onboard charging module mounted behind driver-side rear wheel well (accessible from underneath). Remove three T30 Torx screws securing protective cover. Locate Level 1 cable connector (marked with yellow label). Press connector release tab and pull connector straight out. Support cable weight to prevent strain on connector.
7
Remove Cable Assembly from Vehicle
From charging port location, carefully pull cable assembly through door frame channel while assistant guides cable from underneath to prevent snagging. Remove cable completely and inspect routing path for any damage or debris that needs cleaning before new cable installation.
8
Route New Cable Through Underbody
Beginning at onboard charging module location, route new Level 1 cable along driver-side frame rail following original path. Ensure cable maintains minimum 2-inch clearance from exhaust components, suspension members, and sharp edges. Install new cable ties at frame rail brackets but do not fully tighten yet.
9
Connect Cable to Onboard Charging Module
Align Level 1 cable connector with onboard charging module receptacle (yellow-labeled port). Push connector in firmly until click is heard and connector is fully seated. Verify orange safety lock tab engages. Reinstall charging module protective cover with three T30 Torx screws.
10
Route Cable Through Door Frame Channel
Feed cable through B-pillar door frame channel from underneath toward charging port. Ensure cable follows original routing path and does not interfere with door operation. Install new cable retention clips in original locations. Verify cable has appropriate slack and is not under tension.
11
Connect Cable to Charging Port Module
At charging port, align Level 1 cable connector with port module receptacle. Push connector in firmly and rotate clockwise 1/4 turn until orange safety tab locks. Tug gently on cable to verify secure connection. Inspect seal between connector and port module.
12
Secure Final Cable Routing
Return to underside of vehicle and verify cable routing maintains proper clearances throughout suspension travel. Tighten all cable ties securely but not excessively tight (cable should not be compressed). Reinstall protective conduit sections. Verify no cable rubbing or contact points.
13
Test Charging System Function
Reconnect 12V auxiliary battery negative terminal. Power on vehicle and check for any charging system fault codes using instrument cluster. Plug in Level 1 charging cable to known good 120V outlet. Verify charging indicator illuminates and charging begins normally. Monitor for 5 minutes to confirm stable charging operation.

Reassembly

Reinstall charging port inner cover with four T20 Torx screws, ensuring port light connector is properly seated
Reinstall door sill trim plate by aligning clips and pressing firmly until seated
Reinstall driver-side lower rocker panel trim by engaging front clips first then pressing rear section until all clips engage
Lower vehicle from lift or jack stands
Close charging port door and verify door closes and latches properly

Verification

Perform full Level 1 charging cycle test using factory 120V charging cable and verify proper charging rates (approximately 1.2-1.4 kW)
Verify no charging system fault codes present in vehicle diagnostics
Inspect all cable routing points for proper clearance and secure retention
Verify charging port door opens and closes smoothly without binding
Test drive vehicle over varied road surfaces and re-inspect cable routing for any looseness or rubbing
Verify charging port light illuminates when port door is opened
Confirm cable does not interfere with driver door operation throughout full range of motion

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