Charge Port Seal

This procedure replaces the charge port seal on a 2023 Rivian EDV 500 to prevent moisture intrusion and ensure proper sealing of the charging interface.

Warnings

Tools required

Parts

• Charge port seal assembly × 1 — Use OEM specification
• Charge port trim clips (if damaged) × 4 — Use OEM specification

Preparation

1. Ensure vehicle is parked on level ground with parking brake applied
2. Power off the vehicle completely and remove key fob at least 10 feet away from vehicle
3. Verify no charging cable is connected and charge port door closes properly
4. Clean the exterior charge port area with water and mild soap, then dry completely
5. Allow charge port to reach ambient temperature if vehicle was recently charged

Procedure

1. 1

   Access charge port compartment
   Manually open the charge port door by pressing the release button on the driver's side of the door. If vehicle is completely powered off, use the manual release lever located behind a small access panel on the inside edge of the charge port door frame. Insert plastic trim tool and gently release the door to full open position.
2. 2

   Remove charge port trim panel
   Locate the four T20 Torx screws securing the charge port trim bezel. Remove all four screws and set aside. Carefully pull the trim bezel away from the body, starting at the bottom edge. Disconnect the charge port lighting connector by pressing the release tab and pulling straight out. Remove trim bezel completely.
3. 3

   Access charge port assembly mounting
   With trim removed, locate the three T25 Torx bolts securing the charge port assembly to the body. Remove only the top two bolts at this stage, leaving the bottom bolt partially threaded to support the assembly weight. Note the position of any ground straps or wire routing clips attached to these bolts.
4. 4

   Disconnect charge port communication harness
   Identify the main charge port communication connector (gray connector with orange secondary lock). Slide the orange secondary lock away from the connector body. Press the primary connector release tab and pull straight back to disconnect. Secure the connector away from the work area using a zip tie or tape to prevent it from falling behind the panel.
5. 5

   Support and remove charge port assembly
   Support the charge port assembly with one hand. Remove the final bottom T25 Torx bolt. Carefully pull the charge port assembly forward approximately 2 inches to access the rear seal mounting area. Do not pull assembly completely out as internal wiring harness has limited slack.
6. 6

   Remove old charge port seal
   Inspect the existing seal for the seal retention clips or adhesive backing. The factory seal uses a combination of mechanical clips and adhesive. Carefully pry the seal away from the charge port housing starting at the bottom using a plastic trim tool. Work around the perimeter slowly to avoid damaging the charge port housing. Remove all remnants of old adhesive using isopropyl alcohol and lint-free cloth.
7. 7

   Clean and inspect sealing surfaces
   Thoroughly clean both the charge port housing seal groove and the body panel sealing surface with isopropyl alcohol. Inspect for any cracks, deformation, or damage to the housing. Check that all seal retention clips in the housing are intact and not broken. Allow surfaces to dry completely before proceeding.
8. 8

   Install new charge port seal
   Remove protective backing from new seal if present. Starting at the top center of the charge port assembly, align the seal into the retention groove. Press firmly along the entire perimeter ensuring all retention clips engage with audible clicks. Verify seal sits flush around entire circumference with no gaps or twisted sections. Apply light silicone lubricant to outer seal lip if provided in kit.
9. 9

   Reinstall charge port assembly
   Carefully guide the charge port assembly back into the body opening, ensuring the new seal aligns properly with the body panel mating surface. Insert and hand-thread all three T25 Torx bolts. Tighten bolts in a cross-pattern (top, bottom, middle) to ensure even seal compression. Reattach any ground straps or wire routing clips removed earlier.
10. 10

    Reconnect electrical connections
    Reconnect the main charge port communication connector ensuring it clicks fully into place. Slide the orange secondary lock back into the locked position until it stops. Reconnect the charge port lighting connector to the trim bezel by aligning and pressing until the release tab clicks.
11. 11

    Reinstall trim panel
    Position the charge port trim bezel ensuring the lighting connector is routed properly and not pinched. Align all mounting points and press the bezel into place. Install all four T20 Torx screws and tighten in a cross-pattern to ensure even trim panel seating. Verify trim panel sits flush with surrounding body panels.
12. 12

    Test charge port operation
    Power on the vehicle. Test charge port door operation using both the vehicle touchscreen and the button on the charge port door itself. Verify the charge port lighting illuminates when door opens. Close and open the door three times to confirm seal is not interfering with door operation.

Reassembly

1. Ensure all Torx fasteners are tightened and none were left loose or missing
2. Verify charge port trim bezel is flush and all clips are fully engaged
3. Confirm no tools or parts were left in the charge port compartment
4. Check that charge port door opens and closes smoothly without binding

Verification

• Perform a complete visual inspection of the seal around the entire charge port perimeter for proper seating and no gaps
• Connect a charging cable and verify proper connection and locking mechanism engagement
• Monitor for any fault codes related to charge port communication after completing installation
• Perform a water test by gently spraying water around the charge port door seal (door closed) and inspecting for any water intrusion into the charge port cavity
• Complete a full charging session and verify no moisture warning indicators appear on the vehicle display

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle