Charge Port Latch

This procedure covers the removal and replacement of the charge port latch assembly on a 2025 Rivian EDV 500, restoring proper charge port door operation.

Warnings

Tools required

Parts

• Charge port latch assembly × 1 — Use OEM specification
• Trim panel retaining clips × 1 — As needed for damaged clips

Preparation

1. Ensure vehicle is unplugged from any charging equipment and charging is fully stopped
2. Park vehicle on level surface and engage parking brake
3. Open charge port door using vehicle touchscreen or mobile app
4. Disconnect 12V battery negative terminal and wait 5 minutes
5. Verify charge port area is clean and free from debris

Procedure

1. 1

   Access charge port compartment
   Manually open the charge port door if not already open. Use a plastic pry tool to carefully release the inner trim panel surrounding the charge port opening. Start at the bottom edge and work around the perimeter, releasing approximately 8-10 retaining clips. Remove the trim panel and set aside in a safe location.
2. 2

   Remove charge port weather seal
   Carefully peel back the rubber weather seal from around the charge port opening. This seal is adhered with weatherproof adhesive. Work slowly to avoid tearing the seal. If replacing the latch only, this seal will be reused.
3. 3

   Disconnect charge port latch electrical connector
   Locate the electrical connector attached to the latch assembly near the top of the charge port housing. Press the locking tab and carefully pull the connector straight out. If connector is difficult to remove, use an electrical connector removal tool to depress internal locking tabs.
4. 4

   Remove latch mounting fasteners
   Using a T25 Torx driver, remove the two upper mounting screws securing the latch mechanism to the charge port housing. Using a T20 Torx driver, remove the lower mounting screw. Support the latch assembly while removing the final fastener to prevent it from falling.
5. 5

   Extract latch assembly from housing
   Carefully pull the latch assembly forward and away from the charge port housing. Note the position of any alignment pins or guides. There is a cable or linkage connected to the door mechanism - gently disconnect this by sliding the cable end out of its retaining slot on the latch mechanism.
6. 6

   Inspect charge port housing and door mechanism
   With latch removed, inspect the charge port housing for any debris, corrosion, or damage. Use a shop vacuum to remove any dirt or foreign material. Check the door pivot points and ensure smooth operation. Apply a small amount of dielectric grease to door pivot points if needed.
7. 7

   Prepare new latch assembly
   Remove the new latch assembly from packaging and compare with old unit to verify correct part. Check that the latch mechanism operates smoothly by manually actuating it. Verify the electrical connector matches the harness connector.
8. 8

   Install new latch assembly
   Position the new latch assembly in the charge port housing, aligning any guide pins or alignment features. Reconnect the door linkage cable by sliding the cable end into the retaining slot on the latch mechanism. Ensure the cable is properly seated and the door moves when the latch is actuated.
9. 9

   Secure latch mounting fasteners
   Install and hand-tighten the lower T20 mounting screw first to hold the latch in position. Install the two upper T25 mounting screws and hand-tighten. Tighten all three screws in a star pattern to ensure even seating. Screws should be snug but not over-torqued as they thread into plastic housing.
10. 10

    Reconnect latch electrical connector
    Align the electrical connector and press firmly until you hear and feel a positive click. Gently tug on the connector to verify it is locked in place. Ensure wiring harness is routed properly and not pinched or strained.
11. 11

    Reinstall weather seal and trim panel
    Reposition the rubber weather seal around the charge port opening, ensuring it is fully seated in its groove around the entire perimeter. Align the inner trim panel with its mounting location and press firmly around all edges to engage the retaining clips. Verify panel is flush and secure.
12. 12

    Reconnect 12V battery
    Reconnect the 12V battery negative terminal and tighten securely. The vehicle systems will initialize, which may take 1-2 minutes.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all trim panels are properly secured with no gaps or misalignment
3. Confirm weather seal is properly positioned to prevent water intrusion

Verification

• Using the vehicle touchscreen or mobile app, command the charge port door to open and close multiple times - verify smooth operation with no binding or unusual noises
• Manually press the charge port door closed and verify the latch engages and holds the door securely shut
• Connect a charging cable to the port and verify the latch releases properly when unlocked
• Check for any warning lights or error messages related to the charge port on the vehicle display
• Perform a test charge session to confirm full functionality of the charge port system

Related trouble codes on this vehicle

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