Charge Port Assembly

This procedure covers the removal and replacement of the charge port assembly on a 2023 Rivian EDV 500, including disconnection of the high-voltage electrical connections and mounting hardware.

Warnings

Tools required

Parts

• Charge port assembly × 1 — Use OEM specification
• Charge port gasket/seal × 1 — Use OEM specification
• High-voltage connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure the vehicle is not plugged into a charging cable
3. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Put on high-voltage safety gloves rated for at least 1000V
5. Use diagnostic tool to verify high-voltage system is in safe service mode
6. Document any active fault codes related to the charging system before beginning work
7. Open the charge port door fully and inspect for any obvious damage or debris

Procedure

1. 1

   Remove charge port door and trim panel
   Open the charge port door to its fully open position. Using plastic trim tools, carefully release the trim panel clips around the charge port opening. Remove the interior trim panel to expose the charge port assembly mounting hardware. There are typically 4-6 plastic clips securing this panel.
2. 2

   Disconnect charge port status LED connector
   Locate the charge port LED status light connector behind the trim panel. Press the connector release tab and gently pull the connector straight out from the LED module. This is a low-voltage connector with a locking tab on one side.
3. 3

   Disconnect charge port communication module connector
   Identify the charge port communication module connector (typically a gray or black multi-pin connector). Press the locking tab and disconnect the connector. This connector handles vehicle-to-charger communication signals.
4. 4

   Remove charge port mounting fasteners
   Using the appropriate Torx driver (typically T25 or T30), remove the mounting bolts securing the charge port assembly to the body panel. There are usually 4-6 bolts arranged around the perimeter of the charge port. Support the charge port assembly with one hand while removing the final fasteners to prevent it from falling.
5. 5

   Verify high-voltage system de-energized
   Before proceeding to disconnect high-voltage cables, use your high-voltage capable multimeter to verify zero voltage on the orange high-voltage cables connected to the charge port. Test between both positive and negative terminals, and between each terminal and vehicle ground. Confirm readings of 0V DC.
6. 6

   Disconnect high-voltage positive cable
   Wearing high-voltage safety gloves, locate the orange high-voltage positive cable connected to the charge port assembly. Remove the locking mechanism (typically a sliding lock or bolt). Pull the connector straight out from the charge port assembly. The connector may require significant force but should not be twisted. Place a non-conductive cover over the exposed connector end.
7. 7

   Disconnect high-voltage negative cable
   Locate the orange high-voltage negative cable connected to the charge port assembly. Remove the locking mechanism and pull the connector straight out from the charge port. Cover the exposed connector end with a non-conductive material. Keep positive and negative connectors separated.
8. 8

   Remove charge port assembly
   With all electrical connections disconnected, carefully pull the charge port assembly out through the body panel opening. Inspect the mounting area for any damage, corrosion, or debris. Note the orientation of the assembly and the routing of all cables for reinstallation.
9. 9

   Clean mounting surface and inspect seals
   Clean the charge port mounting surface on the body panel using a wire brush or appropriate cleaning tool. Remove any old gasket material, dirt, or corrosion. Inspect the body panel opening for any damage that could compromise the seal. Ensure the new charge port gasket is included with the replacement assembly.
10. 10

    Install new charge port assembly
    Position the new charge port gasket on the body panel mounting surface. Route the high-voltage cables through the appropriate openings. Align the new charge port assembly with the mounting holes and carefully insert it into the body panel opening. Ensure the gasket remains properly positioned during installation.
11. 11

    Connect high-voltage cables
    Connect the high-voltage negative cable first, ensuring the connector seats fully into the charge port assembly. Install and secure the locking mechanism. Then connect the high-voltage positive cable, ensuring full seating and secure locking. Apply dielectric grease to connector seals if specified by manufacturer. Verify both connections are secure and properly locked.
12. 12

    Install mounting fasteners
    Install all charge port mounting bolts and tighten in a cross-pattern to ensure even pressure on the gasket. Since no specific torque values are provided in the database, tighten fasteners snugly but do not over-torque plastic or composite components. Verify the charge port assembly sits flush against the body panel with no gaps.
13. 13

    Reconnect communication and LED connectors
    Reconnect the charge port communication module connector, ensuring it clicks into place and the locking tab engages. Reconnect the LED status light connector. Verify all connectors are fully seated and secured.
14. 14

    Reinstall trim panel and test charge port door
    Align the interior trim panel and press firmly to engage all plastic clips. Verify the trim panel is secure and flush with surrounding body panels. Test the charge port door operation to ensure it opens and closes smoothly without binding or interference.
15. 15

    System verification and programming
    Reconnect the 12V battery negative terminal. Use the Rivian diagnostic tool to clear any stored fault codes and perform charge port module programming or configuration if required. Follow the diagnostic tool prompts to complete any module initialization procedures. Run a charging system functionality test through the diagnostic tool.

Reassembly

1. Ensure all trim panels and fasteners are properly secured
2. Verify charge port door opens and closes smoothly
3. Confirm all electrical connectors are fully seated and locked
4. Check that the charge port gasket is properly sealed with no gaps

Verification

• Using the diagnostic tool, verify no fault codes are present related to the charging system
• Test charge port LED indicators illuminate correctly when the charge port door is opened
• Connect a compatible charging cable and verify the vehicle recognizes the charger connection
• Monitor the first charging session to confirm proper charging functionality and communication between vehicle and charger
• Verify the charge port door locks and unlocks properly during charging
• Inspect the charge port area for any coolant or fluid leaks around the mounting gasket
• Test vehicle-to-charger communication by initiating a charge session through the vehicle interface

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