This procedure covers the replacement of the Level 2 charging cable assembly on a 2025 Rivian EDV 500 delivery van, including cable removal, connector inspection, and installation verification.

Warnings

Tools required

Parts

• Level 2 charging cable assembly × 1 — Use OEM specification
• Cable retention clips × 4 — Use OEM specification
• Charge port seal gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is fully powered off and removed from any charging source
3. Open rear cargo doors and driver door for interior access
4. Disconnect 12V battery negative terminal and wait 5 minutes for capacitor discharge
5. Place high voltage service disconnect warning tags on steering wheel
6. Access service mode through center display if still accessible before battery disconnect

Procedure

1. 1

   Remove driver side lower dash panel
   Using trim removal tools, carefully pry out the lower dash panel below the steering column. Remove four T30 Torx screws securing the panel. Disconnect any electrical connectors for diagnostic port or lights. Set panel aside in safe location.
2. 2

   Access charge port module compartment
   Open the charge port door on driver side front fender. Remove three T40 Torx screws securing the charge port module cover from inside the port opening. Carefully pull cover forward to access internal wiring and connectors.
3. 3

   Verify system isolation
   Using digital multimeter set to DC voltage, verify no voltage is present at the charge port pins. Test between each charging pin and vehicle ground. All readings must be 0V before proceeding. If any voltage is detected, stop and investigate.
4. 4

   Disconnect charge port electrical connectors
   Locate the main charge port connector behind the port module. Press the orange connector lock tab and carefully disconnect the primary HV connector. Disconnect the secondary communication connector (gray, 8-pin) by depressing the release tab. Document connector orientation with photos.
5. 5

   Remove cable retention points
   Follow the charging cable routing from the port toward the battery compartment under the vehicle. Remove cable retention clips along the driver side frame rail. Use 10mm socket to remove four bolts securing cable routing brackets. Support cable weight as brackets are removed.
6. 6

   Access battery management system compartment
   From underneath vehicle, locate the BMS compartment on driver side of battery pack. Remove six T40 Torx screws securing the lower access panel. Lower panel carefully and support to prevent damage. Identify charging cable terminal connection point.
7. 7

   Disconnect cable from BMS module
   Wearing insulated gloves, locate the charging cable terminal connections at the BMS. Remove the orange safety lock by sliding it toward the rear of vehicle. Use 13mm socket to remove two terminal nuts securing positive and negative cable leads. Carefully extract terminals and cap with insulating covers.
8. 8

   Remove old charging cable assembly
   Working from charge port end, carefully pull cable through routing channels along frame rail. Guide cable past any sharp edges or obstacles. Remove cable completely from vehicle and inspect routing path for any damage or debris. Clean routing channels with compressed air if available.
9. 9

   Inspect charge port and connections
   Thoroughly inspect charge port pins for any discoloration, pitting, or damage. Check port seal gasket for wear or deterioration and replace if necessary. Inspect BMS terminal connections for corrosion. Clean all connection points with electrical contact cleaner if needed.
10. 10

    Route new charging cable
    Begin routing new cable from BMS compartment toward charge port. Follow original cable path along driver side frame rail. Ensure cable does not contact any sharp edges, moving components, or heat sources. Leave slight slack at both ends for connection without tension.
11. 11

    Connect cable to BMS module
    Remove insulating caps from new cable terminals. Connect positive and negative terminals to BMS connection points, ensuring correct polarity. Install terminal nuts using 13mm socket and tighten firmly. Install orange safety lock by sliding fully into locked position. Verify lock is fully seated.
12. 12

    Secure cable routing
    Install cable retention clips along frame rail routing path at original locations. Use 10mm socket to reinstall four routing bracket bolts and tighten securely. Verify cable is properly supported and does not hang below frame or contact suspension components. Add cable ties at factory locations.
13. 13

    Connect charge port connectors
    Apply small amount of dielectric grease to charge port connector pins if new gasket was installed. Connect gray 8-pin communication connector until it clicks into place. Connect main HV connector ensuring orange lock tab fully engages. Tug gently on both connectors to verify secure connection.
14. 14

    Reinstall access panels
    Reinstall BMS compartment lower access panel and secure with six T40 Torx screws. Reinstall charge port module cover and secure with three T40 Torx screws. Reinstall driver side lower dash panel, reconnect electrical connectors, and secure with four T30 Torx screws.
15. 15

    Reconnect 12V battery and initialize
    Reconnect 12V battery negative terminal. Remove high voltage warning tags. Power on vehicle and allow all systems to initialize fully. Check center display for any HV system warnings or faults. Clear any stored diagnostic codes related to charging system using service mode.

Reassembly

1. Ensure all access panels are fully secured and trim pieces are properly seated
2. Verify all electrical connectors are locked and properly sealed
3. Confirm cable routing does not interfere with any moving parts or suspension travel
4. Check that charge port door opens and closes properly without binding

Verification

• With vehicle powered on, verify charge port indicator lights illuminate when port door is opened
• Connect a Level 2 charging station and verify vehicle recognizes charger and begins charging sequence
• Monitor first charging session for at least 15 minutes to ensure stable charging with no interruptions
• Check for any warning lights or messages on center display related to charging system
• Verify charging cable does not generate excessive heat during charging session
• Perform visual inspection underneath vehicle to confirm no interference with cable routing
• Test charge port communication by checking charging rate and scheduled charging features through vehicle interface

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