Charge Port Seal

This procedure replaces the charge port seal on a 2025 Rivian EDV 500 to prevent water intrusion and ensure proper charging port function.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is not plugged in and is not in charging mode
3. Open the charge port door and verify no charging cable is connected
4. Disconnect the 12V battery negative terminal and wait 5 minutes
5. Gather all tools and new charge port seal
6. Clean the exterior area around the charge port with isopropyl alcohol

Procedure

1. 1

   Access charge port door mechanism
   Open the charge port door fully. Use a trim panel removal tool to carefully release the charge port door trim panel from the body. Start at the bottom edge and work around the perimeter to release all clips. Remove the trim panel and set aside.
2. 2

   Remove charge port door assembly
   Locate the T20 Torx screws securing the charge port door hinge mechanism (typically 2-3 screws). Remove these screws and carefully disconnect the charge port door release cable by pressing the tab and sliding the cable end from the bracket. Set the door assembly aside.
3. 3

   Disconnect charge port electrical connector
   Locate the main charge port electrical connector behind the charge port assembly. Press the locking tab and carefully pull the connector straight back to disconnect. Note the routing of the wiring harness for reassembly.
4. 4

   Remove charge port assembly fasteners
   Using a T25 Torx driver, remove the four bolts securing the charge port assembly to the vehicle body. Support the assembly while removing the final bolt to prevent it from falling.
5. 5

   Remove charge port assembly
   Carefully pull the charge port assembly straight out from the vehicle body opening. Angle it as needed to clear any wiring or brackets. Place the assembly on a clean work surface with the seal facing up.
6. 6

   Remove old charge port seal
   Inspect the existing seal for the retention method (press-fit or secured with clips). Use plastic pry tools to carefully release the old seal from the charge port housing groove. Work around the perimeter slowly to avoid damaging the housing. Remove and discard the old seal.
7. 7

   Clean sealing surfaces
   Thoroughly clean the seal groove in the charge port housing using isopropyl alcohol and a lint-free cloth. Remove all old seal residue, dirt, and contamination. Inspect the groove for damage or debris. Allow surfaces to dry completely.
8. 8

   Prepare new seal
   Remove the new charge port seal from packaging and inspect for damage. Apply a thin layer of dielectric grease to the seal bead that will contact the charge port housing. This aids installation and provides additional moisture protection.
9. 9

   Install new charge port seal
   Starting at the bottom center of the charge port housing, press the new seal firmly into the groove. Work around the perimeter in both directions, ensuring the seal seats completely and evenly in the groove. Check that all edges are properly seated and there are no gaps or twisted sections.
10. 10

    Reinstall charge port assembly
    Position the charge port assembly with the new seal into the vehicle body opening. Align the mounting holes and ensure the wiring harness routes properly without pinching. Hand-start all four T25 Torx bolts before tightening any. Tighten bolts in a cross pattern to ensure even seal compression.
11. 11

    Reconnect electrical connector
    Reconnect the main charge port electrical connector, ensuring it clicks into place and the locking tab is fully engaged. Verify the connection is secure by gently tugging on the connector.
12. 12

    Reinstall charge port door
    Reconnect the charge port door release cable to the bracket mechanism, ensuring it clicks into place. Position the door assembly and install the T20 Torx hinge screws. Tighten securely and verify door operation by manually opening and closing several times.
13. 13

    Reinstall trim panel
    Align the charge port door trim panel with the body opening. Press firmly around all edges to engage the retaining clips. Verify all clips are seated by checking for gaps around the perimeter.
14. 14

    Reconnect battery and test
    Reconnect the 12V battery negative terminal. Power on the vehicle and use the charge port release button to test door operation. Verify the door opens smoothly and closes properly. Check for any error messages related to the charge port.

Reassembly

1. Ensure all electrical connections are secure and properly locked
2. Verify charge port door opens and closes smoothly without binding
3. Check that all trim panels are fully seated with no gaps
4. Confirm no tools or parts are left in the charge port area

Verification

• Test charge port door operation using the interior button and exterior touch activation (if equipped)
• Inspect the new seal visually for proper seating and no gaps around the entire perimeter
• Plug in a charging cable and verify proper fitment and no loose connection feel
• Start a charging session to confirm the vehicle recognizes the connection and begins charging normally
• After the first charging session, inspect the seal area for any signs of moisture intrusion or seal displacement
• Verify no charge port error codes are present in the vehicle system

Related trouble codes on this vehicle

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