DC Fast Charge Port

This procedure covers the removal and replacement of the DC fast charge port assembly on a 2022 Rivian EDV 500 delivery van.

Warnings

Tools required

Parts

• DC fast charge port assembly × 1 — Use OEM specification
• Charge port seal/gasket × 1 — Use OEM specification
• Charge port door assembly (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is fully powered down and key fob is at least 10 feet away from vehicle
3. Connect diagnostic tool and access Rivian service software
4. Document any fault codes related to charging system before beginning work
5. Locate DC fast charge port on driver side rear quarter panel
6. Take photos of existing installation for reference during reassembly

Procedure

1. 1

   Disable high voltage system
   Using Rivian service software, navigate to high voltage service mode and disable the high voltage system. Follow all software prompts to ensure proper shutdown sequence. Verify system is disabled and obtain lockout confirmation from software. Wait minimum 5 minutes for capacitor discharge.
   ⚠️Do not proceed until service software confirms high voltage system is disabled and locked out.
2. 2

   Disconnect 12V battery
   Open rear equipment bay and locate 12V battery. Disconnect negative terminal first, then positive terminal. Isolate terminals to prevent accidental reconnection during service.
   ⚠Wait 2 minutes after disconnecting 12V battery to allow control modules to power down completely.
3. 3

   Remove charge port door
   Open the DC fast charge port door fully. Using a plastic trim tool, carefully release the door hinge clips from the inside. Support the door while removing to prevent damage. Disconnect the door position sensor connector if equipped.
4. 4

   Access charge port mounting area
   From inside the cargo area, locate and remove the driver side rear interior trim panel. Remove Torx screws securing panel and carefully pull trim away to expose charge port assembly mounting area. Disconnect any electrical connectors for interior lighting as needed.
5. 5

   Verify voltage isolation
   Put on insulated gloves. Using a multimeter, verify zero voltage present at the charge port terminals. Check between each terminal and vehicle ground. All readings must be zero volts before proceeding.
   ⚠️If any voltage is detected, stop work immediately and verify high voltage system was properly disabled. Do not proceed until zero voltage is confirmed.
6. 6

   Disconnect charge port electrical connectors
   Locate the high voltage charging cable connector and communication harness connector on the back of the charge port assembly. Release connector locks and carefully disconnect both connectors. Note orientation and routing for reinstallation.
   ⚠Do not pull on wires. Press release tabs and pull on connector bodies only.
7. 7

   Remove charge port coolant lines
   Locate coolant lines connected to charge port assembly for cable cooling. Place drain pan below connections. Release quick-connect fittings or remove hose clamps and carefully disconnect coolant lines. Cap or plug lines immediately to prevent fluid loss and contamination.
   ⚠Coolant may be warm. Allow system to cool if vehicle was recently charged.
8. 8

   Remove charge port mounting fasteners
   Remove all mounting bolts securing the charge port assembly to the body. There are typically 4-6 fasteners around the perimeter. Support the charge port assembly while removing final fastener to prevent it from falling.
9. 9

   Remove charge port assembly
   Carefully pull the charge port assembly straight out from the body opening. Guide electrical and coolant connections through the opening. Remove the port seal/gasket from the body and inspect mounting surface for damage or corrosion.
10. 10

    Prepare new charge port
    Unpack new DC fast charge port assembly and verify all components are present. Inspect connectors for any shipping damage. Install new port seal/gasket onto the new charge port assembly. Apply thin layer of dielectric grease to electrical connectors if recommended by service manual.
11. 11

    Install new charge port assembly
    Guide coolant lines and electrical connectors through body opening first. Align charge port assembly with mounting holes and press into position. Verify seal is properly seated around entire perimeter. Install mounting bolts and tighten in a star pattern to ensure even pressure on seal.
12. 12

    Reconnect coolant lines
    Remove caps from coolant lines. Connect coolant lines to new charge port assembly, ensuring quick-connects fully engage with audible click or hose clamps are properly tightened. Verify routing does not create kinks or stress on connections.
13. 13

    Reconnect electrical connectors
    Connect high voltage charging cable connector and communication harness connector to new charge port assembly. Ensure connectors are fully seated and locking tabs engage properly. Verify correct orientation and routing matches original installation.
14. 14

    Reinstall interior trim and charge door
    Reinstall driver side rear interior trim panel and secure with Torx screws. Reconnect any interior lighting connectors. Align charge port door with hinges and press into place until clips engage. Connect door position sensor if equipped. Verify door opens and closes smoothly.
15. 15

    Reconnect 12V battery and enable high voltage system
    Reconnect 12V battery, positive terminal first then negative terminal. Using Rivian service software, exit high voltage service mode and re-enable the high voltage system. Follow all software prompts and verify system initializes without faults.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm all interior trim panels are properly secured
3. Check charge port door operation for smooth opening and closing
4. Verify no tools or parts were left in cargo area or near charge port

Verification

• Using diagnostic tool, verify no fault codes are present related to charging system
• Test charge port door operation through vehicle interface
• Perform a test charge session with a DC fast charger to verify proper communication and charging function
• Monitor charge port temperature during initial charge session to verify cooling system operation
• Check coolant connections for any leaks after charging session
• Verify charge port LED indicators function properly during charge initiation
• Confirm vehicle charging history logs show successful DC fast charge session

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