Onboard Charger R&R

This procedure covers the removal and replacement of the onboard charger module on a 2025 Rivian EDV 500 dual motor AWD electric delivery vehicle.

Warnings

Tools required

Parts

• Onboard charger module × 1 — Use OEM specification
• HV connector seals × 2 — Use OEM specification
• Thermal interface pad × 1 — Use OEM specification
• Coolant hose clamps × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is not plugged into charging source
3. Access Rivian diagnostic software and log into vehicle
4. Use diagnostic software to place HV system in service mode
5. Disconnect 12V battery negative terminal and wait 2 minutes
6. Put on high voltage safety gloves and protective equipment
7. Open front hood and locate HV service disconnect under access panel
8. Remove HV service disconnect plug and store in locked area away from vehicle
9. Wait minimum 15 minutes for HV system capacitor discharge
10. Use multimeter to verify zero voltage at onboard charger HV terminals
11. Place HV lockout tags and barriers around work area
12. Position coolant drain pan under vehicle near onboard charger location

Procedure

1. 1

   Access onboard charger compartment
   Remove the lower front access panel from driver side of vehicle. The onboard charger is mounted in the front compartment near the charge port inlet. Remove plastic covers and fasteners securing access panel. Set aside hardware for reinstallation.
2. 2

   Disconnect coolant lines
   Locate the two coolant lines connected to the onboard charger module. Using hose clamp pliers, compress and slide clamps away from connections. Carefully twist and pull coolant hoses from charger inlet and outlet ports. Allow coolant to drain into collection pan. Plug open hose ends with appropriate caps to prevent contamination.
3. 3

   Disconnect charge port cable
   Locate the AC input cable from the charge port assembly to the onboard charger. This is a shielded low voltage AC cable (not orange HV cable). Disconnect the connector by pressing release tab and carefully pulling connector straight out. Secure cable away from work area.
4. 4

   Disconnect CAN communication connector
   Locate the vehicle CAN bus connector on the side of the onboard charger module. Press the connector lock tab and carefully disconnect the communication harness. Note connector orientation for reinstallation.
5. 5

   Verify HV system de-energized
   Using the high voltage multimeter, verify zero voltage at the HV DC output terminals of the onboard charger. Test between positive and negative terminals, then each terminal to chassis ground. All readings must be zero volts before proceeding. Document voltage readings.
6. 6

   Disconnect HV DC output cable
   The orange HV cable connects charger output to the battery system. Remove the safety cover from the HV connector. Using insulated tools, remove the HV connector locking mechanism (typically two bolts or locking lever). Carefully pull the HV connector straight out from charger. Place non-conductive cover over exposed HV terminals.
7. 7

   Remove charger mounting fasteners
   Locate all mounting bolts securing the onboard charger to its bracket (typically 4-6 bolts around perimeter). Using appropriate socket, remove all mounting bolts while supporting the weight of the charger module. The charger weighs approximately 25-30 lbs, so ensure proper support.
8. 8

   Remove onboard charger module
   Carefully maneuver the onboard charger module out of its mounting location. Watch for any remaining wire harness connections or brackets that may still be attached. Remove charger from vehicle and place on clean work surface. Inspect mounting area for any coolant leaks or damage.
9. 9

   Prepare new onboard charger
   Unpack new onboard charger module and verify part number matches application. Inspect all ports and connectors for shipping damage. Install new thermal interface pad onto mounting surface if required. Apply fresh thermal paste to coolant port threads if specified by manufacturer.
10. 10

    Install new onboard charger
    Carefully position new onboard charger module into mounting location, ensuring proper alignment with mounting holes and ensuring thermal interface pad contacts mounting surface properly. Start all mounting bolts by hand before tightening any. Torque mounting bolts in cross pattern to ensure even pressure distribution.
11. 11

    Reconnect HV DC output cable
    Remove protective covers from HV connectors. Inspect HV connector pins for any damage or contamination. Align and carefully insert HV connector into charger output port, ensuring proper seating. Install new HV connector seal if provided. Secure locking mechanism and verify connection is fully locked. Install safety cover over HV connection.
12. 12

    Reconnect communication and AC input
    Reconnect CAN bus communication connector to charger, ensuring positive lock engagement. Reconnect AC input cable from charge port to charger input, ensuring connector is fully seated and locked. Verify all connector locks are engaged.
13. 13

    Reconnect coolant lines
    Remove caps from coolant hoses. Inspect coolant ports on new charger for any shipping plugs and remove if present. Push coolant hoses firmly onto charger inlet and outlet ports until fully seated. Install new hose clamps and position them properly over hose connections. Tighten clamps securely.
14. 14

    Refill and bleed coolant system
    Add EV Battery/Motor Coolant to system through designated fill point. Follow Rivian bleeding procedure to remove air from cooling system. Run coolant pump using diagnostic software to circulate coolant. Check for leaks at all charger coolant connections. Top off coolant as needed to proper level.
15. 15

    System verification and programming
    Reinstall all access panels and covers. Reconnect 12V battery. Using Rivian diagnostic software, configure and program new onboard charger module to vehicle. Clear any stored fault codes. Exit HV service mode. Reinstall HV service disconnect plug. Use diagnostic software to verify onboard charger is communicating properly and ready for operation.

Reassembly

1. Reinstall all access panels and covers removed during disassembly
2. Verify all fasteners are properly tightened
3. Ensure no tools or parts are left in HV compartment
4. Remove HV lockout tags only after all work is complete and verified

Verification

• Use Rivian diagnostic software to verify onboard charger module communication with vehicle systems
• Check for any active fault codes related to charging system
• Verify coolant level is correct and no leaks are present at charger connections
• Perform functional test by plugging vehicle into Level 2 charger and verifying charging initiates properly
• Monitor charging for at least 15 minutes to ensure stable operation and no error messages
• Verify charge port indicator lights function correctly during charging
• Check that vehicle displays correct charging status and estimated time to full charge
• Confirm no coolant leaks after charging system has reached operating temperature

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