Charge Port Assembly

This procedure covers the removal and replacement of the charge port assembly on a 2022 Rivian EDV 500, including disconnecting the high-voltage system and replacing the complete charging port unit.

Warnings

Tools required

Parts

• Charge port assembly × 1 — Use OEM Rivian specification
• Charge port trim bezel × 1 — Use OEM specification if damaged
• Charge port wiring harness connector seals × 1 — Use OEM specification if damaged

Preparation

1. Park the vehicle on a level surface and engage the parking brake
2. Ensure the vehicle is powered off and the key fob is at least 20 feet away from the vehicle
3. Verify no charging cable is connected to the charge port
4. Open the rear cargo doors to access the high-voltage service disconnect
5. Disconnect the 12V battery negative terminal and wait 5 minutes
6. Don high-voltage safety gloves rated for at least 1000V
7. Locate and remove the high-voltage service disconnect cover in the rear cargo area
8. Remove the HV service disconnect plug and install the provided lockout device
9. Use a high-voltage meter to verify zero voltage at the charge port terminals
10. Document the current charge port configuration with photos for reassembly reference

Procedure

1. 1

   Access the charge port area
   The charge port is located on the driver's side rear quarter panel. Open the charge port door by pressing the release button or manually if power is disconnected. Use plastic trim tools to carefully pry the interior charge port bezel away from the body panel, starting at the bottom edge and working around the perimeter. Disconnect any interior lighting connectors if equipped.
2. 2

   Remove exterior trim panel
   From the exterior, use a T25 Torx driver to remove the four screws securing the charge port outer trim ring. Carefully pull the trim ring away from the body, being mindful of any clips. Set the trim ring aside in a protected area to prevent scratching.
3. 3

   Disconnect charge port electrical connectors
   With the high-voltage gloves still on, locate the main charge port connector at the rear of the assembly. Press the connector lock tab and carefully disconnect the high-voltage connector. Inspect the connector for any signs of arcing, burning, or corrosion. Next, disconnect the low-voltage communication connector (typically gray or white) by pressing the release tab. Finally, disconnect the charge port lock actuator connector if equipped.
4. 4

   Remove charge port mounting fasteners
   Locate the four 10mm bolts securing the charge port assembly to the body structure. These are typically arranged in a square pattern around the charge port housing. Use a 10mm socket and ratchet to remove all four bolts. Support the charge port assembly with one hand while removing the final bolt to prevent it from falling.
5. 5

   Extract charge port assembly
   Carefully pull the charge port assembly straight out from the body opening. Guide the wiring harness through the body opening as you remove the assembly. Inspect the mounting surface and body opening for any debris, corrosion, or damage. Clean the mounting surface with a wire brush or contact cleaner if necessary.
6. 6

   Inspect and prepare new charge port
   Remove the new charge port assembly from its packaging. Inspect all connectors and terminals for any shipping damage or contamination. Verify that all mounting brackets and hardware are included. Apply a thin coat of dielectric grease to the high-voltage connector terminals on the new charge port to ensure proper contact and corrosion resistance.
7. 7

   Install new charge port assembly
   Guide the wiring harness through the body opening and position the new charge port assembly into the mounting location. Align the mounting holes with the body structure. Insert all four 10mm mounting bolts and hand-tighten them first. Once all bolts are started, tighten them in a cross pattern to ensure even seating of the assembly. Since no torque specification is provided, tighten securely but do not over-torque.
8. 8

   Reconnect electrical connectors
   While wearing high-voltage gloves, reconnect the high-voltage connector to the charge port assembly. Ensure the connector seats fully and the locking tab clicks into place. Reconnect the low-voltage communication connector, ensuring it locks properly. If equipped, reconnect the charge port lock actuator connector. Verify all connectors are fully seated and secured.
9. 9

   Install exterior and interior trim
   Position the exterior charge port trim ring and secure it with the four T25 Torx screws, tightening them evenly. Reconnect any interior lighting connectors if equipped. Snap the interior charge port bezel back into position, ensuring all clips are properly seated and the bezel sits flush with the surrounding panel.
10. 10

    Restore vehicle power systems
    Return to the rear cargo area and reinstall the high-voltage service disconnect plug, ensuring it is fully seated and the cover is secured. Reconnect the 12V battery negative terminal. Remove the lockout device and store it in the vehicle's service kit location.
11. 11

    Initialize and test charge port
    Power on the vehicle and use the Rivian diagnostic tool to clear any stored high-voltage system fault codes. Run the charge port function test through the diagnostic software if available. Test the charge port door operation using the vehicle's controls. Verify the charge port lock actuator operates correctly by listening for the lock/unlock sound.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all trim pieces are properly aligned and secured
3. Check that the charge port door opens and closes smoothly without binding
4. Confirm no tools or parts have been left in the work area
5. Secure any loose wiring with cable ties to prevent rattling or interference

Verification

• Power on the vehicle and verify no warning lights or fault codes related to the charging system are present
• Use the vehicle's touchscreen to verify the charge port status shows as available/ready
• Test the charge port door operation from both the vehicle controls and the key fob
• Plug in a compatible charging cable and verify the vehicle recognizes the connection and begins the charging handshake process
• Check for proper illumination of the charge port light ring if equipped
• Verify the charge port lock engages when a charging cable is connected
• Inspect the installation area for any gaps in trim or loose components
• Take a short test drive and re-inspect all connections and mounting points for any signs of looseness or abnormal noise

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