This procedure covers the replacement of the Level 2 charging cable assembly on the 2024 Rivian EDV 500 electric delivery vehicle, including connector, cable routing, and electrical verification.

Warnings

Tools required

Parts

• Level 2 charging cable assembly × 1 — Use OEM specification
• Cable retention clips × 4 — Use OEM specification
• Cable ties (heavy duty) × 10 — Use OEM specification
• Wire loom protective sleeve × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered off and key fob is at least 20 feet away from vehicle
3. Open rear cargo doors and access battery compartment area
4. Disconnect 12V auxiliary battery negative terminal
5. Access high voltage service disconnect located in rear battery compartment and remove service plug
6. Wait minimum 10 minutes for high voltage system capacitor discharge
7. Verify system is de-energized using approved high voltage testing equipment
8. Remove driver side lower dashboard panel to access charging system control module
9. Photograph existing cable routing for reference during reinstallation

Procedure

1. 1

   Remove charging port access panel
   Open the charging port door on the driver side front fender. Remove the three Torx screws securing the inner charging port panel. Carefully pull the panel away from the body, disconnecting any lighting connectors. Set panel aside in a safe location.
2. 2

   Disconnect charging cable from charge port controller
   Locate the charge port controller module mounted behind the charging port. Press the locking tab on the main connector and carefully pull the charging cable connector straight out from the controller. Inspect the connector pins for any signs of corrosion or damage.
3. 3

   Remove driver side wheel well liner
   Remove the driver side front wheel well liner by removing the eight plastic push clips and two screws. Pull the liner forward to access the cable routing path from the charge port through the wheel well area.
4. 4

   Trace and release cable routing clips
   Follow the charging cable from the port through the wheel well area toward the battery compartment. Release all cable retention clips along the frame rail and inner fender. Cut cable ties as needed, noting their positions for reinstallation. Be careful not to damage any adjacent wiring harnesses.
5. 5

   Access battery management system compartment
   From the rear cargo area, remove the access panel to the battery management system (BMS) compartment. This requires removing six bolts securing the composite panel. Lift the panel carefully as it contains sound deadening material.
6. 6

   Disconnect cable from battery management system
   Locate the charging cable terminus at the BMS module. Press the orange safety locking lever down, then press the connector release tab. Pull the high voltage connector straight out from the BMS charging input port. Place the orange safety cap over the exposed BMS connector immediately.
7. 7

   Remove cable from vehicle
   Working from rear to front, carefully pull the charging cable through the routing channel along the driver side frame rail. Remove any remaining clips or guides. Guide the cable through the wheel well grommet and remove it completely from the vehicle. Inspect the routing channel for any debris or damage.
8. 8

   Prepare new charging cable
   Unpack the new Level 2 charging cable assembly and inspect for any shipping damage. Verify all connectors have protective caps installed. Check that the cable matches the original in length and connector configuration. Remove protective caps only immediately before installation.
9. 9

   Route new cable through vehicle
   Starting from the charge port end, route the new cable through the wheel well grommet, along the driver side frame rail channel toward the rear battery compartment. Ensure the cable follows the exact same path as the original, avoiding any sharp edges or potential pinch points. Do not fully secure yet.
10. 10

    Connect cable to battery management system
    Remove the orange safety cap from the BMS charging input port. Align the high voltage connector with the port, ensuring proper orientation using the keyed connector design. Push firmly until the connector fully seats and you hear an audible click. Verify the orange safety lever locks into the secured position.
11. 11

    Secure cable routing
    Install all cable retention clips along the frame rail at their original positions. Use new heavy-duty cable ties to secure the cable at intervals no greater than 12 inches. Ensure the cable has slight slack and is not under tension. Verify the cable does not contact any moving components or sharp edges.
12. 12

    Connect cable to charge port controller
    At the front charge port location, remove the protective cap from the cable connector. Align the connector with the charge port controller module and push firmly until the locking tab clicks into place. Gently tug on the cable to verify secure connection.
13. 13

    Reinstall high voltage service disconnect
    Return to the rear battery compartment. Inspect the high voltage service disconnect plug for any damage. Reinstall the service plug fully into its receptacle until it locks into place. Verify the safety indicator shows the system is ready for energization.
14. 14

    Reconnect 12V battery and power up vehicle
    Reconnect the 12V auxiliary battery negative terminal. Ensure all connections are secure. Bring the key fob near the vehicle and power on the vehicle using the normal start procedure. Monitor the dashboard for any high voltage system warnings or charging system faults.

Reassembly

1. Reinstall the battery management system compartment access panel with all six bolts
2. Reinstall the driver side wheel well liner with all clips and screws
3. Reinstall the charging port access panel and reconnect any lighting connectors
4. Close the charging port door
5. Reinstall the lower dashboard panel
6. Verify all removed panels and components are properly secured
7. Clean any fingerprints or debris from charging port area

Verification

• Using the vehicle touchscreen, navigate to charging settings and verify the Level 2 charging option is available and shows no faults
• Plug in a known-good Level 2 charger and verify the vehicle recognizes the connection and begins charging sequence
• Monitor the charging process for at least 5 minutes to ensure stable charging with no interruptions or error messages
• Verify the charging indicator lights on the charge port illuminate correctly
• Check that estimated time to full charge displays properly on the dashboard
• Perform a visual inspection under the vehicle to ensure no cables are hanging or improperly routed
• Test drive the vehicle briefly and verify no high voltage system warnings appear
• Document the repair with charging cable part number and date of installation in vehicle service records

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