Charge Port Latch

This procedure involves removing and replacing the charge port latch assembly on a 2024 Rivian EDV 500, which controls the locking and release mechanism of the charging cable.

Warnings

Tools required

Parts

• Charge port latch assembly × 1 — Use OEM specification
• Charge port weatherstrip seal × 1 — Use OEM specification
• Trim panel clips (replacement) × 5 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is unlocked and charge port door can be manually opened
3. Disconnect any active charging sessions and ensure no charging is scheduled
4. Locate the charge port on the driver side front fender
5. Disconnect the 12V battery using the service disconnect located under the front hood
6. Wait minimum 5 minutes for electrical system capacitors to fully discharge
7. Open the charge port door fully and inspect for obvious damage or obstructions

Procedure

1. 1

   Remove charge port door trim panel
   Using plastic trim removal tools, carefully pry the charge port door trim panel from the outer edge. Release the retaining clips by working around the perimeter. Pull the trim panel outward and set aside. Note the location of each clip for reinstallation.
2. 2

   Disconnect charge port lighting connector
   Locate the LED lighting connector behind the charge port door trim. Press the locking tab and disconnect the connector by pulling straight back. Secure the connector away from the work area.
3. 3

   Access charge port latch assembly
   Remove the three T25 Torx screws securing the inner charge port access panel. Carefully pull the panel forward to reveal the latch mechanism and wiring harness. Take note of wire routing for reassembly.
4. 4

   Disconnect latch electrical connector
   Locate the latch assembly electrical connector with orange locking tab. Depress the orange secondary lock and slide it back. Press the primary connector release tab and carefully disconnect the connector from the latch assembly. Inspect connector pins for corrosion or damage.
5. 5

   Remove latch mounting fasteners
   Remove the two T30 Torx screws securing the latch assembly to the charge port housing. Support the latch assembly with one hand while removing the second screw to prevent it from falling into the fender cavity.
6. 6

   Remove charge port latch assembly
   Carefully maneuver the latch assembly out of the charge port housing. Note the orientation of the latch mechanism and the position of the actuator arm. Check for any cable ties or additional wiring that may be securing the assembly.
7. 7

   Inspect charge port housing and weatherstrip
   With the latch removed, inspect the charge port housing for debris, moisture, or damage. Clean the mounting surface with a lint-free cloth. Inspect the weatherstrip seal for tears or deterioration. Replace if damaged.
8. 8

   Install new weatherstrip seal
   If replacing the weatherstrip, remove the old seal from the charge port housing groove. Clean the groove thoroughly. Install the new weatherstrip by pressing it firmly into the groove, starting at the bottom and working around the perimeter to ensure proper seating.
9. 9

   Position new latch assembly
   Position the new charge port latch assembly in the housing, aligning the actuator arm with the charge port lock mechanism. Ensure the latch orientation matches the original installation. Verify no wires are pinched between the latch and housing.
10. 10

    Install latch mounting fasteners
    Install the two T30 Torx screws to secure the latch assembly. Start both screws by hand before tightening to ensure proper alignment. Tighten screws evenly in a cross pattern to prevent binding of the latch mechanism. Do not overtighten as this can cause the latch to bind.
11. 11

    Reconnect latch electrical connector
    Route the latch wiring harness following the original path. Connect the electrical connector to the latch assembly, ensuring it clicks into place. Slide the orange secondary lock forward to fully secure the connection. Gently tug the connector to verify it is locked.
12. 12

    Reinstall charge port access panel
    Position the inner access panel and verify proper wire routing behind it. Install the three T25 Torx screws to secure the panel. Ensure the panel sits flush against the charge port housing.
13. 13

    Reconnect charge port lighting
    Connect the LED lighting connector to the charge port door trim. Ensure the connector is fully seated and locked. Test the connection by gently pulling on the wire.
14. 14

    Reinstall charge port door trim panel
    Align the charge port door trim panel with the mounting location. Press firmly around all edges to engage the retaining clips. Replace any broken clips as needed. Verify the trim panel is secure and flush with surrounding bodywork.
15. 15

    Reconnect 12V battery and initialize system
    Reconnect the 12V battery service disconnect. Wait 30 seconds for the vehicle systems to initialize. The vehicle may perform a self-test routine. Close all doors and allow the vehicle to enter sleep mode if needed before testing.

Reassembly

1. Ensure all electrical connectors are fully seated and locked with secondary locks engaged
2. Verify all trim panels are properly secured and aligned with no gaps
3. Confirm all fasteners are installed and properly tightened without over-torquing
4. Check that no tools or parts were left in the charge port area or fender cavity

Verification

• Open and close the charge port door electrically using the vehicle touchscreen to verify door operation
• Insert a charging cable and verify the latch engages and locks the cable securely
• Attempt to remove the charging cable while locked to confirm latch holds properly
• Unlock the charge port from the touchscreen and verify the cable releases smoothly
• Test charge port lighting to ensure illumination functions correctly when door is open
• Perform a test charging session to confirm full charge port functionality
• Inspect for any unusual noises or binding during latch operation
• Check for proper weatherstrip sealing by visually inspecting the charge port door closure

Related trouble codes on this vehicle

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