Charge Port Seal

This procedure covers the replacement of the charge port seal on a 2024 Rivian EDV 500 electric delivery van to prevent water intrusion and ensure proper charging connection.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Ensure vehicle is powered off completely using the main power button.
3. Disconnect the 12V battery negative terminal and wait minimum 5 minutes for high-voltage system discharge.
4. Open the charge port door fully using the interior release or vehicle touchscreen.
5. Inspect the charge port area for debris, water damage, or corrosion.
6. Clean the surrounding area of the charge port with a dry cloth to prevent contamination during seal replacement.

Procedure

1. 1

   Remove charge port door assembly
   Using a plastic trim tool, carefully pry the charge port door from its hinges starting at the bottom edge. Release the retention clips by applying gentle outward pressure. Disconnect any lighting harness if equipped by pressing the release tab and pulling straight out.
2. 2

   Remove charge port trim panel
   Locate the trim panel surrounding the charge port opening on the exterior body panel. Using appropriate Torx driver (typically T25), remove the fasteners securing the trim panel. There are typically 4-6 fasteners around the perimeter. Carefully pull the trim panel away from the body, releasing any remaining retention clips.
3. 3

   Access charge port assembly mounting
   With the trim panel removed, locate the charge port assembly mounting points. Remove the Torx fasteners (typically T30) securing the charge port assembly to the body structure. Support the charge port assembly with one hand while removing the final fastener to prevent it from falling.
4. 4

   Disconnect charge port electrical connector
   Locate the main electrical connector on the back of the charge port assembly. Press the connector release tab and pull the connector straight back to disconnect. Note the routing of any additional ground wires or secondary connectors and disconnect them as needed.
5. 5

   Remove charge port assembly
   Carefully pull the charge port assembly forward through the body panel opening. Maneuver the assembly to clear any wiring or structure behind it. Place the assembly on a clean work surface with the seal facing upward for inspection and removal.
6. 6

   Remove old charge port seal
   Inspect how the seal is retained to the charge port assembly (typically press-fit or clip-retained). Carefully pry or pull the old seal from the charge port assembly, working around the perimeter. Note the orientation and seating position of the seal for proper installation of the new seal.
7. 7

   Clean sealing surfaces
   Using isopropyl alcohol (90% or higher) and lint-free cloths, thoroughly clean all sealing surfaces on the charge port assembly. Remove any residue, old sealant, dirt, or debris. Inspect the sealing groove for damage or deformation. Allow surfaces to dry completely before proceeding.
8. 8

   Inspect charge port contacts
   With the assembly accessible, visually inspect the charging contacts inside the port for corrosion, burn marks, or damage. Check that all contacts move freely and spring back when pressed. If any damage is noted, the entire charge port assembly may require replacement beyond just the seal.
9. 9

   Install new charge port seal
   Position the new seal at the starting point (typically top center) and ensure correct orientation by aligning any locating features. If applicable, apply a thin layer of dielectric-safe silicone lubricant to the seal lip to ease installation. Press the seal firmly into the groove, working around the perimeter in both directions until it seats completely. Verify the seal is fully seated with no gaps or twisted sections.
10. 10

    Reinstall charge port assembly
    Guide the charge port assembly back through the body panel opening, being careful not to pinch wiring. Reconnect the main electrical connector by pushing firmly until it clicks into place. Reconnect any ground wires or secondary connectors. Loosely install the mounting fasteners and align the assembly properly before fully tightening in a cross-pattern.
11. 11

    Reinstall charge port trim panel
    Position the trim panel over the charge port assembly, aligning all mounting holes and clip locations. Press the panel firmly to engage retention clips. Install all Torx fasteners and tighten evenly, ensuring the panel sits flush with the body surface without gaps.
12. 12

    Reinstall charge port door
    If the lighting harness is present, reconnect it first by pushing the connector together until it clicks. Align the charge port door hinges with their mounting points and press firmly until all retention clips engage. Verify the door opens and closes smoothly without binding.

Reassembly

1. Reconnect the 12V battery negative terminal and ensure secure connection.
2. Power on the vehicle and verify all systems initialize normally.
3. Operate the charge port door using both the touchscreen and interior release to confirm proper function.
4. Verify the charge port door closes flush and latches securely.

Verification

• Perform a visual inspection of the installed seal, ensuring it is uniformly seated with no gaps, twists, or protrusions.
• Connect a charging cable to verify proper fit and that the seal compresses appropriately around the connector.
• Initiate a charging session to confirm electrical connectivity and that the vehicle recognizes the charger.
• Perform a water test by spraying light water around the sealed charge port (with door closed) and inspecting for any intrusion after 5 minutes.
• Check for any warning lights or fault codes related to the charging system using the vehicle touchscreen.
• Verify the charge port lighting (if equipped) functions correctly when the door is opened.

Related trouble codes on this vehicle

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