Onboard Charger R&R

This procedure covers the removal and replacement of the onboard charger module on the 2024 Rivian EDV 500, including high-voltage system isolation and electrical disconnections.

Warnings

Tools required

Parts

• Onboard charger module × 1 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification
• Thermal interface pad × 1 — Use OEM specification
• Cable ties × 10 — UV-resistant automotive grade

Preparation

1. Ensure vehicle is on level ground with parking brake applied and wheels chocked
2. Verify AC charging cable is disconnected and charging port door is closed
3. Connect Rivian diagnostic software and log any existing fault codes
4. Perform high-voltage system shutdown procedure through diagnostic software
5. Open frunk and locate 12V battery disconnect switch, rotate to OFF position
6. Wait minimum 15 minutes for high-voltage system capacitor discharge
7. Don high-voltage safety gloves rated for Class 0 (1000V) minimum
8. Remove lower front belly pan to access underside components

Procedure

1. 1

   Verify high-voltage system de-energization
   Using high-voltage multimeter, verify zero voltage at high-voltage service disconnect point near battery pack. Voltage must read 0V DC before proceeding. Use shorting probe on all high-voltage connections to be disturbed during this procedure.
2. 2

   Remove front underbody shield
   Remove all fasteners securing the front underbody shield that covers the onboard charger area. There are typically 12-14 plastic push clips and 6 bolts. Carefully lower shield and set aside.
3. 3

   Disconnect low-voltage connector
   Locate the 12V control connector on the side of the onboard charger module. Depress the locking tab and carefully pull the connector straight back to disconnect. Note connector orientation for reinstallation.
4. 4

   Disconnect AC input connector
   Locate the AC input connector coming from the charge port. This is typically an orange high-voltage connector. Slide the locking collar back and rotate counterclockwise approximately 1/4 turn, then pull straight out. Inspect connector pins and seals for damage.
5. 5

   Disconnect DC output connector
   Locate the DC high-voltage output connector that feeds the battery pack. Slide the orange safety lock forward, then depress the release mechanism and pull connector straight back. This connector may require significant force to disconnect.
6. 6

   Remove coolant lines
   Using quick-disconnect tool if needed, disconnect the inlet and outlet coolant lines from the onboard charger. Have drain pan ready as approximately 1-2 cups of EV Battery/Motor Coolant will drain. Cap or plug lines to prevent contamination.
7. 7

   Remove mounting brackets
   Remove the mounting bolts securing the onboard charger to the vehicle chassis. Typically there are 4-6 mounting bolts. Support the weight of the charger module as you remove the final bolts to prevent it from dropping.
8. 8

   Remove onboard charger
   Carefully maneuver the onboard charger module out of its mounting location. The unit weighs approximately 30-40 lbs. Take care not to damage surrounding wiring harnesses or coolant lines. Inspect mounting area for debris or damage.
9. 9

   Prepare new onboard charger
   Unpack replacement onboard charger and verify part number matches. Install new thermal interface pad on mounting surface if required. Apply thin layer of dielectric grease to all high-voltage connector sealing surfaces. Verify all new connector seals are properly seated.
10. 10

    Install new onboard charger
    Carefully position the new onboard charger into mounting location, ensuring all connectors are accessible and no wiring is pinched. Thread mounting bolts by hand first to ensure proper alignment before tightening progressively.
11. 11

    Reconnect coolant lines
    Reconnect both coolant lines to the onboard charger, ensuring quick-disconnect fittings are fully seated and locked. Tug gently on each line to verify secure connection.
12. 12

    Reconnect DC output connector
    Align and push DC high-voltage connector onto onboard charger output terminal until it clicks into place. Slide orange safety lock back to locked position. Verify connector is fully seated with no gaps visible.
13. 13

    Reconnect AC input connector
    Align AC input connector and push straight in while rotating clockwise 1/4 turn until locking collar engages. Verify connector is secure and orange safety indicator shows proper engagement.
14. 14

    Reconnect low-voltage connector
    Align and push the 12V control connector onto the onboard charger until locking tab clicks into place. Ensure connector is fully seated and secure.
15. 15

    System initialization
    Reinstall front underbody shield with all fasteners. Reconnect 12V battery by rotating disconnect switch to ON position. Use Rivian diagnostic software to initialize the new onboard charger, clear any installation-related codes, and perform charging system functional test. Monitor for any fault codes and verify all connections before final checkout.

Reassembly

1. Ensure all high-voltage connectors are properly locked with orange safety mechanisms engaged
2. Verify coolant lines are secure and no leaks are present
3. Replace any cable ties that were cut during removal with new UV-resistant ties
4. Ensure all wiring harnesses are properly routed and not in contact with sharp edges or heat sources
5. Reinstall all underbody panels and verify all fasteners are secure

Verification

• Using diagnostic software, verify onboard charger is communicating with vehicle control systems with no fault codes
• Perform charging system functional test: connect AC charging cable and verify charging initiates properly
• Monitor charging for 10-15 minutes to ensure proper operation and no overheating
• Verify charging rate matches expected values for the AC source being used
• Check coolant level in reservoir and top off with EV Battery/Motor Coolant if necessary
• Verify no coolant leaks around onboard charger connections
• Test drive vehicle briefly and verify no warning lights or messages appear on instrument cluster

More procedures for this vehicle