DC Fast Charge Port

This procedure covers the removal and installation of the DC fast charge port assembly on a 2023 Rivian EDV 500, including disconnecting high-voltage circuits and replacing the charging port hardware.

Warnings

Tools required

Parts

• DC fast charge port assembly × 1 — Use OEM specification
• Charge port gasket/seal × 1 — Included with port assembly or order separately
• High-voltage connector seals × 2 — Use OEM specification
• Charge port door assembly (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is not connected to any charging equipment
3. Power down the vehicle completely using the infotainment system power-off procedure
4. Wait 2 minutes for vehicle systems to enter sleep mode
5. Disconnect the 12V auxiliary battery negative terminal located in the front trunk compartment
6. Don high-voltage safety gloves and verify they are free from damage
7. Place high-voltage warning signs around the work area
8. Access the HV service disconnect located under the rear seat area and remove it per Rivian service procedures
9. Wait a minimum of 5 minutes for high-voltage system capacitor discharge
10. Use a CAT III multimeter to verify zero voltage across high-voltage bus terminals

Procedure

1. 1

   Remove charge port door and cover
   Open the driver-side rear charge port door fully. Remove the charge port cover by releasing the clips on both sides. Pull the cover forward and disconnect the charge port door motor connector (if equipped with motorized door). Set the cover and door assembly aside.
2. 2

   Access charge port mounting area
   From inside the cargo area, remove the driver-side rear interior panel. Remove T25 Torx screws securing the panel (typically 6-8 screws). Carefully pull the panel away to access the rear side of the charge port assembly. Disconnect any panel clips and set the panel aside in a protected area.
3. 3

   Disconnect low-voltage connections
   Locate the charge port control module connector behind the charge port assembly. Press the connector lock tab and disconnect the low-voltage communication harness. Disconnect the charge port door actuator connector if not already disconnected. Disconnect any LED status light connectors.
4. 4

   Document high-voltage cable routing
   Before disconnecting high-voltage cables, photograph or document the exact routing of both positive and negative DC fast charge cables. Note the locations of all cable retainers and tie-down points. This documentation is critical for proper reassembly.
5. 5

   Verify high-voltage system is de-energized
   Using a CAT III multimeter, verify zero voltage between the DC+ and DC- terminals at the charge port. Verify zero voltage between each terminal and vehicle ground. Do not proceed if any voltage is detected. Record voltage readings for documentation.
6. 6

   Disconnect high-voltage DC cables
   While wearing high-voltage gloves, remove the protective covers from the high-voltage connectors at the charge port. Use a 13mm socket to loosen the connector retaining bolts. Carefully disconnect both the positive (orange cable with red marking) and negative (orange cable with blue marking) high-voltage cables. Immediately cap exposed connectors with protective covers to prevent contamination.
7. 7

   Release cable management
   Cut or release all cable ties and retaining clips securing the high-voltage cables to the charge port assembly and surrounding structure. Leave sufficient slack in the cables for reassembly. Do not bend cables sharply or stress the high-voltage connectors.
8. 8

   Remove charge port mounting fasteners
   Remove all T30 Torx bolts securing the charge port assembly to the body structure (typically 4-6 bolts around the perimeter). Support the charge port assembly from the exterior side while removing the final fasteners to prevent it from falling.
9. 9

   Extract charge port assembly
   Carefully pull the charge port assembly outward from the exterior of the vehicle. Guide high-voltage cables and low-voltage harnesses through the body opening. Remove the assembly completely and place it on a clean, non-conductive work surface. Inspect the mounting area for damage or contamination.
10. 10

    Inspect and prepare new charge port
    Inspect the new charge port assembly for any shipping damage. Verify all gaskets and seals are properly seated. Apply a thin layer of dielectric grease to high-voltage connector pins on the new port assembly. Ensure the charge port door mechanism operates smoothly before installation.
11. 11

    Install new charge port assembly
    Feed high-voltage cables and low-voltage harnesses through the body opening from inside the cargo area. Position the charge port assembly into the mounting location from the exterior, ensuring the gasket is properly aligned. Thread mounting bolts by hand to avoid cross-threading, then tighten in a star pattern to ensure even seating.
12. 12

    Reconnect high-voltage cables
    Remove protective caps from high-voltage connectors. Inspect connector pins for damage or contamination. Connect the negative (blue-marked) cable first, followed by the positive (red-marked) cable. Ensure connectors are fully seated and install new high-voltage seals if required. Torque retaining bolts per manufacturer specification using insulated tools. Install protective covers over all high-voltage connections.
13. 13

    Secure cable management
    Route high-voltage cables exactly as documented in step 4. Install new cable ties at all original retention points. Ensure cables have no sharp bends and are not in contact with body edges or moving components. Verify at least 25mm clearance from all heat sources and moving parts.
14. 14

    Reconnect low-voltage connections
    Reconnect the charge port control module connector until it clicks into place. Reconnect the charge port door actuator connector and LED status light connectors. Verify all connectors are fully seated and locked.
15. 15

    Reinstall interior panel and charge port cover
    Reinstall the cargo area interior panel, ensuring all clips are properly engaged. Install and tighten all T25 Torx screws. From the exterior, reconnect the charge port door motor connector (if equipped). Install the charge port cover by engaging the clips on both sides. Verify the charge port door opens and closes smoothly.

Reassembly

1. Reinstall the high-voltage service disconnect under the rear seat area
2. Reconnect the 12V auxiliary battery negative terminal in the front trunk
3. Ensure all tools and materials are removed from the vehicle
4. Remove high-voltage warning signs from work area

Verification

• Power up the vehicle and verify no high-voltage isolation fault codes are present using diagnostic tool
• Check charge port status indicators illuminate correctly on the vehicle display
• Test charge port door operation (manual and motorized if equipped)
• Connect a DC fast charger and verify proper communication handshake occurs
• Perform a brief DC fast charge session (5-10 minutes) and monitor for proper operation, normal temperatures, and no error messages
• Verify charge port LED status lights function correctly during charging
• Inspect all high-voltage connections for signs of heat or arcing after test charge
• Clear any stored diagnostic codes and verify no new codes appear
• Test vehicle drive functions to ensure high-voltage system operates normally

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