DC Fast Charge Port

This procedure covers the removal and replacement of the DC fast charge port assembly on a 2024 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• DC fast charge port assembly × 1 — Use OEM specification
• Charge port door gasket × 1 — Use OEM specification
• Cable sealing grommets × 2 — Use OEM specification
• Push-pin fastener assortment × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure vehicle is not connected to any charging equipment
3. Open rear cargo doors for access to electrical service panel
4. Photograph charge port assembly and wiring connections for reference during reassembly
5. Ensure you have high voltage safety equipment and training before proceeding

Procedure

1. 1

   Disconnect 12V battery
   Locate the 12V auxiliary battery in the rear cargo area behind the driver-side panel. Remove the negative terminal first using a 10mm socket, then remove the positive terminal. Secure cables away from battery posts. Wait minimum 5 minutes for system capacitor discharge.
2. 2

   Access high voltage service disconnect
   Open the HV service disconnect panel located in the rear cargo area. Using high voltage safety gloves, remove the HV service disconnect by pulling the orange handle straight out. Verify with multimeter that no voltage is present at the disconnect terminals.
3. 3

   Remove charge port door and exterior trim
   Locate the DC fast charge port on the driver side of the vehicle behind the driver door. Open the charge port door fully. Remove the interior rubber gasket seal. Use a T30 Torx driver to remove the four screws securing the charge port door hinge assembly. Carefully remove the door and set aside.
4. 4

   Access charge port mounting area
   From inside the cargo area, locate and remove the driver-side interior panel behind the charge port location. Remove push-pin fasteners and carefully pull panel away from body. You should now have access to the rear of the charge port assembly and wiring harnesses.
5. 5

   Disconnect charge port electrical connectors
   Wearing high voltage safety gloves, identify the main HV DC fast charge connector (orange) and the communication/control connector (gray). Press the release tab on the communication connector and carefully disconnect. For the HV connector, slide the orange safety lock to the unlock position, then press the connector release and carefully separate.
6. 6

   Disconnect cooling lines (if equipped)
   If your charge port assembly has active cooling, identify the inlet and outlet coolant lines. Place drain pan underneath connections. Use quick-disconnect tool to release coolant line fittings. Cap open lines immediately to prevent contamination and fluid loss.
7. 7

   Remove charge port mounting fasteners
   From the exterior side, remove the three T40 Torx bolts securing the charge port assembly to the body panel. Support the charge port assembly from behind while removing the final bolt to prevent it from falling.
8. 8

   Extract charge port assembly
   Carefully guide the charge port assembly and attached wiring harness through the body opening from the exterior. Route the connectors and cables through carefully to avoid snagging on body panel edges. Inspect the body opening gasket and replace if damaged.
9. 9

   Prepare new charge port assembly
   Unpack new DC fast charge port assembly and inspect for damage. Install new cable sealing grommets onto the wiring harness pass-through. Apply thin coating of dielectric grease to HV connector terminals and communication pins as specified by manufacturer. Verify charge port door gasket is properly seated on new assembly.
10. 10

    Install new charge port assembly
    From the exterior, carefully insert the new charge port assembly into the body opening, guiding wiring harnesses through from inside. Align mounting holes and hand-start all three T40 Torx mounting bolts. Tighten bolts in a cross pattern to ensure even seating against body panel.
11. 11

    Reconnect electrical connectors
    Wearing high voltage safety gloves, reconnect the communication/control connector first until it clicks into place. Then connect the HV DC connector, ensuring it fully seats. Slide the orange safety lock to the locked position. Verify both connectors are fully engaged with no gaps.
12. 12

    Reconnect cooling lines (if equipped)
    If charge port has active cooling, reconnect coolant line quick-disconnect fittings. Push firmly until you hear/feel the click indicating full engagement. Gently tug on lines to verify secure connection. Check coolant level in reservoir and top off if needed with EV Battery/Motor Coolant.
13. 13

    Reinstall interior panel and charge port door
    Reinstall the interior cargo panel, ensuring all clips and fasteners are properly secured. From exterior, reinstall the charge port door assembly using the four T30 Torx screws. Install the rubber gasket seal around the charge port opening. Verify door opens and closes smoothly.
14. 14

    Restore power and initialize system
    Reinstall the HV service disconnect by pushing the orange handle firmly into place until fully seated. Reconnect 12V battery positive terminal first, then negative terminal. Power on the vehicle and allow the charging system to initialize. Check instrument cluster for any high voltage system warnings.

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify charge port door opens and closes without binding or interference
3. Confirm all interior panels and fasteners are properly reinstalled
4. Check that charge port gasket seals properly when door is closed

Verification

• Using the vehicle touchscreen, navigate to charging settings and verify DC fast charge port is recognized by the system
• Perform a visual inspection of the charge port interior for proper alignment and no visible damage
• Connect to a DC fast charging station and verify charging initiates properly and communication is established
• Monitor first charging session for any error codes, unusual sounds, or excessive heat at the charge port
• Verify charge port door locks and unlocks properly when commanded by vehicle system
• Check for any coolant leaks around charge port area after first charge cycle (if equipped with cooling)

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