Charge Port Assembly

This procedure covers the removal and replacement of the charge port assembly on a 2025 Rivian EDV 500, including disconnection of high-voltage components and reinstallation.

Warnings

Tools required

Parts

• Charge port assembly × 1 — Use OEM specification
• Charge port seal/gasket × 1 — Use OEM specification
• High-voltage connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect charging cable if connected and verify charge port door is closed
3. Chock rear wheels
4. Disconnect negative 12V battery cable and wait 5 minutes minimum for capacitor discharge
5. Verify high-voltage system is de-energized using appropriate multimeter
6. Don high-voltage insulated gloves and safety equipment
7. Open charge port door manually if necessary using emergency release
8. Document charge port wiring connections with photos for reference during reassembly

Procedure

1. 1

   Access charge port assembly
   Remove the charge port door trim panel by carefully releasing retaining clips. On the Rivian EDV 500, access the charge port from inside the driver side front fender area. Remove the inner fender liner fasteners (combination of push clips and Torx screws) to expose the rear of the charge port assembly.
2. 2

   Disconnect charge port lighting connector
   Locate the charge port LED lighting harness connector near the top of the assembly. Press the locking tab and carefully disconnect the low-voltage connector. Secure the wire out of the way.
3. 3

   Verify high-voltage isolation
   Using a high-voltage rated multimeter, verify there is no voltage present at the charge port high-voltage terminals. Check between both DC pins and ground, and between the two DC pins. Readings should be 0V. Do not proceed if any voltage is detected.
4. 4

   Disconnect high-voltage charging cables
   Wearing insulated gloves, locate the high-voltage DC charging cable connections at the rear of the charge port assembly. These are typically orange cables. Release the locking mechanism (usually a sliding lock or rotating collar) and carefully disconnect both positive and negative high-voltage cables. Cap or cover exposed terminals immediately with insulating material.
5. 5

   Disconnect communication and ground wires
   Locate and disconnect the charge port communication connector (typically a multi-pin low-voltage connector). Disconnect the ground wire from the charge port assembly by removing the fastener securing the ground lug to the assembly mounting point.
6. 6

   Remove charge port mounting fasteners
   Remove the mounting bolts securing the charge port assembly to the vehicle body. On the EDV 500, there are typically 4-6 mounting bolts accessible from behind the assembly. Support the charge port assembly while removing the final fasteners to prevent it from falling.
7. 7

   Extract charge port assembly
   Carefully pull the charge port assembly rearward and out through the fender opening. The assembly may require slight rotation or angling to clear mounting points. Inspect the charge port seal and mounting area for damage or debris.
8. 8

   Prepare new charge port assembly
   Unpack the new charge port assembly and verify all components are present. Install a new charge port seal/gasket onto the new assembly, ensuring it is properly seated in the groove. Compare the new assembly to the old unit to verify correct part.
9. 9

   Install new charge port assembly
   Guide the new charge port assembly into position through the fender opening, routing all wiring harnesses properly. Align the assembly with mounting holes and ensure the seal is properly positioned against the body panel. Install mounting bolts hand-tight initially, then tighten evenly in a cross-pattern to secure the assembly without distorting the seal.
10. 10

    Reconnect high-voltage cables
    Wearing insulated gloves, reconnect the high-voltage positive and negative cables to the charge port assembly. Ensure connectors are fully seated and locking mechanisms are engaged. Verify cable routing matches original configuration and cables are not pinched or strained.
11. 11

    Reconnect low-voltage connections
    Reconnect the charge port ground wire and secure with fastener. Reconnect the communication connector and LED lighting connector, ensuring all locking tabs engage fully. Verify all connections are secure and properly seated.
12. 12

    Reinstall access panels
    Reinstall the inner fender liner and secure with all original fasteners. Ensure all push clips and Torx screws are properly installed. Reinstall the charge port door trim panel, ensuring retaining clips engage properly.
13. 13

    Reconnect 12V battery
    Reconnect the negative 12V battery cable. The vehicle may require a brief initialization period after battery reconnection.

Reassembly

1. Ensure all high-voltage connections are fully seated and locked before closing panels
2. Verify charge port seal is not pinched or displaced during assembly
3. Ensure all wiring harnesses are properly routed and secured with original clips or new cable ties
4. Confirm charge port door operates smoothly and seals properly when closed

Verification

• Perform charge port functionality test using vehicle display to open and close charge port door
• Verify charge port LED lighting illuminates when door is opened
• Connect a compatible charging cable and verify vehicle recognizes connection and begins charging sequence
• Inspect for any error messages related to charging system on vehicle display
• Check for proper seal by inspecting charge port area for gaps or misalignment
• Perform a test charge session for at least 10 minutes to verify proper operation
• Verify no high-voltage fault codes are present using diagnostic equipment if available

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