Charge Port Assembly

This procedure covers the removal and replacement of the charge port assembly on a 2024 Rivian EDV 500, including disconnection of the high voltage system and associated electrical connectors.

Warnings

Tools required

Parts

• Charge port assembly × 1 — Use OEM specification
• Charge port door seal × 1 — Use OEM specification
• Charge port mounting hardware kit × 1 — Use OEM specification
• High voltage connector seals × 1 — Use OEM specification

Preparation

1. Ensure vehicle is parked on a level surface with parking brake engaged
2. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for systems to power down
3. Verify vehicle is not connected to any charging equipment
4. Connect diagnostic tool and document any existing fault codes
5. Don high voltage safety equipment including insulated gloves and face shield
6. Remove rear cargo area access panels to expose high voltage disconnect location
7. Place high voltage warning tags on steering wheel and charge port

Procedure

1. 1

   Disable High Voltage System
   Using the diagnostic tool, place the vehicle into high voltage service mode. Access the high voltage service disconnect located in the rear cargo area. Remove the service disconnect cover and pull the high voltage disconnect lever to the OFF position. Lock out the disconnect with appropriate safety tag. Wait minimum 10 minutes for high voltage system capacitors to fully discharge.
2. 2

   Verify High Voltage System De-Energized
   Using a high voltage capable multimeter, verify zero voltage is present at the high voltage service disconnect terminals. Test between positive and negative terminals, then test each terminal to vehicle ground. All readings must be below 5V DC before proceeding.
3. 3

   Remove Charge Port Door
   Open the charge port door fully. Locate the two door hinge retaining screws at the top of the door assembly. Remove these screws using a T30 Torx driver. Carefully disconnect the door release actuator connector if equipped. Remove the charge port door and set aside.
4. 4

   Access Charge Port Assembly
   From inside the driver side rear quarter panel area, remove the interior trim panel using plastic trim removal tools. This will expose the backside of the charge port assembly. Remove any sound deadening material that may be covering the charge port mounting bolts.
5. 5

   Disconnect Charge Port Electrical Connectors
   Locate the charge port control module connector (gray 12-pin connector) and the high voltage charge cable connector (orange locking connector). Release the control module connector by pressing the tab and pulling straight back. For the high voltage connector, slide the orange safety lock to the unlocked position, then press the release lever while pulling the connector straight back. Do not twist or bend the high voltage connector.
6. 6

   Disconnect Proximity Detection and Temperature Sensor
   Locate the smaller proximity detection connector (green 6-pin) and temperature sensor connector (black 2-pin) on the charge port assembly. Release both connectors by pressing their locking tabs and pulling straight back. Label these connectors for proper reassembly identification.
7. 7

   Remove Charge Port Mounting Fasteners
   Remove the four mounting bolts securing the charge port assembly to the body using a 10mm socket. Support the charge port assembly from the exterior side while removing the final bolts to prevent it from falling. Note the position of any ground straps or brackets attached to the mounting bolts.
8. 8

   Remove Charge Port Assembly
   Carefully pull the charge port assembly outward from the exterior side of the vehicle. Guide all electrical connectors and wiring through the body opening. Inspect the body opening seal and replace if damaged or torn. Remove and discard the old charge port door seal.
9. 9

   Prepare New Charge Port Assembly
   Inspect the new charge port assembly for any shipping damage. Verify all connector seals are properly seated and in good condition. Apply a thin layer of dielectric grease to the high voltage connector contact surfaces if recommended by service manual. Install the new charge port door seal onto the charge port assembly.
10. 10

    Install New Charge Port Assembly
    Route all electrical connectors through the body opening from the exterior side. Align the charge port assembly with the mounting holes in the body. Verify proper alignment of the charge port opening with the body panel. Install the four mounting bolts with any ground straps or brackets in their original positions. Tighten bolts in a cross pattern to ensure even seating of the assembly.
11. 11

    Reconnect All Electrical Connectors
    Working from inside the quarter panel area, reconnect all electrical connectors in reverse order of removal. Start with the temperature sensor (black 2-pin) and proximity detection (green 6-pin) connectors. Reconnect the control module connector (gray 12-pin), ensuring the locking tab clicks into place. Finally, reconnect the high voltage connector (orange), ensuring it is fully seated before sliding the orange safety lock to the locked position. Verify all connectors are fully engaged and locked.
12. 12

    Reinstall Interior Trim and Charge Port Door
    Reinstall any sound deadening material and the interior trim panel in the quarter panel area. Ensure all trim clips are properly seated. Reconnect the door release actuator connector if equipped. Position the charge port door and install the two hinge retaining screws using a T30 Torx driver. Verify the door opens and closes smoothly.
13. 13

    Re-Enable High Voltage System
    Remove the safety tag from the high voltage service disconnect. Push the high voltage disconnect lever to the ON position. Reinstall the service disconnect cover and rear cargo area access panels. Reconnect the 12V auxiliary battery negative terminal.
14. 14

    Configure and Test Charge Port
    Using the diagnostic tool, take the vehicle out of high voltage service mode. Run the charge port initialization and configuration procedure. Clear any fault codes that were generated during the repair. Verify communication with the charge port control module and verify all sensor readings are within specification.

Reassembly

1. Ensure all electrical connectors are fully seated and locked with proper engagement of safety mechanisms
2. Verify the high voltage connector orange safety lock is in the fully locked position
3. Confirm all interior trim panels are properly reinstalled with all clips engaged
4. Remove all high voltage warning tags from the vehicle

Verification

• Connect a J1772 Level 2 charging cable to the charge port and verify the charge port indicator lights illuminate properly
• Start a charging session and verify the vehicle begins charging without fault codes
• Verify the charge port door opens and closes smoothly using both the button and automatic opening when charging cable is inserted
• Check for proper proximity detection by partially inserting the charging cable and verifying the vehicle recognizes the connection
• Use diagnostic tool to verify all charge port sensors are reading within specification and no fault codes are present
• Verify charge port heating elements function properly if vehicle is equipped with cold weather charging package
• Test emergency manual charge port release mechanism from inside the vehicle to ensure proper function

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