DC Fast Charge Port

This procedure covers removal and replacement of the DC fast charge port assembly on the 2025 Rivian EDV 500, including disconnecting the high-voltage system and replacing the charge port hardware.

Warnings

Tools required

Parts

• DC fast 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
• Trim panel clips (replacement as needed) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is not connected to any charging equipment
3. Verify vehicle has been shut down for at least 10 minutes
4. Don high-voltage safety equipment including insulated gloves and face shield
5. Disable vehicle power by removing 12V service disconnect located in front trunk area
6. Place high-voltage lockout/tagout device on service disconnect
7. Access the high-voltage disconnect located in the rear battery compartment per service manual
8. Open charge port door and inspect for any visible damage or foreign objects
9. Chock rear wheels if working near vehicle exterior panels

Procedure

1. 1

   Disable high-voltage system
   Locate the high-voltage service disconnect in the battery pack area (accessible from underneath rear of vehicle or through service access panel). Wearing high-voltage gloves, unlock and remove the high-voltage service plug. Install lockout/tagout device to prevent reconnection. Wait minimum 5 minutes for high-voltage capacitors to discharge.
   ⚠️Never remove high-voltage service disconnect without proper insulated gloves rated for minimum 1000V.
2. 2

   Verify system de-energization
   Using a high-voltage capable multimeter, verify zero voltage at the high-voltage service disconnect terminals and at the charge port high-voltage connections. Record voltage readings. All measurements must read 0V DC before proceeding.
3. 3

   Remove charge port door and exterior trim
   Open the charge port door fully. Remove the Torx screws securing the charge port door hinge mechanism (typically T25). Disconnect the charge port door light connector if equipped. Remove any exterior trim panels around the charge port opening using trim removal tools.
4. 4

   Access charge port assembly from interior
   From inside the vehicle cargo area, locate and remove the interior side panel corresponding to the charge port location (driver or passenger side depending on vehicle configuration). Remove fasteners securing the access panel (combination of Torx screws and push clips). Set panel aside carefully to avoid damaging clips.
5. 5

   Disconnect charge port wiring harness
   Locate the charge port wiring harness connectors behind the port assembly. Disconnect the low-voltage signal connector first by releasing the locking tab. Label connector orientation if needed for reassembly. Disconnect the charge port lock actuator connector if equipped.
6. 6

   Disconnect high-voltage charge cables
   Wearing high-voltage gloves, identify the two high-voltage DC charge cables (typically orange-colored). Release the connector locking mechanisms and carefully disconnect both positive and negative high-voltage charge cables from the port assembly. Inspect connector seals for damage and replace if necessary. Cap or secure disconnected cables away from work area.
   ⚠️Even after de-energization, treat all orange high-voltage cables as live until proven otherwise with multimeter verification.
7. 7

   Disconnect coolant lines (if equipped)
   If the charge port assembly includes liquid cooling (common on EDV models), locate the coolant inlet and outlet lines. Place drain pan beneath connections. Release quick-connect fittings or loosen hose clamps and disconnect coolant lines. Plug open lines immediately to prevent coolant loss and contamination. Expect minor coolant spillage (less than 1 quart).
8. 8

   Remove charge port mounting hardware
   Remove the mounting bolts or nuts securing the charge port assembly to the vehicle body (typically 4-6 fasteners, combination of 10mm and 12mm). Support the charge port assembly while removing final fasteners to prevent it from falling. Note the location of any ground straps or additional brackets.
9. 9

   Extract charge port assembly
   Carefully withdraw the charge port assembly from the exterior of the vehicle, routing all connectors and cables through the body opening. Inspect the mounting location for any corrosion, damage, or moisture intrusion. Clean mounting surface thoroughly if reusing location.
10. 10

    Install new charge port assembly
    Inspect new charge port assembly for shipping damage and verify correct part number. Install new seal/gasket onto charge port assembly. Position new charge port into body opening from exterior, ensuring proper alignment with mounting holes and that the seal seats correctly against body panel. Insert and hand-tighten mounting bolts.
11. 11

    Secure charge port mounting
    Tighten charge port mounting bolts in a cross-pattern to ensure even sealing pressure. While no specific torque values are provided in the database, tighten securely per manufacturer specifications. Verify charge port assembly is flush with body panel and seal is properly compressed all around.
12. 12

    Reconnect coolant lines (if equipped)
    If equipped with liquid cooling, reconnect coolant inlet and outlet lines to charge port assembly. Ensure quick-connect fittings are fully seated and locked, or tighten hose clamps to manufacturer specification. Verify lines are routed without kinks or sharp bends.
13. 13

    Reconnect high-voltage cables
    Wearing high-voltage gloves, reconnect the positive and negative high-voltage DC charge cables to the new charge port assembly. Ensure connectors are fully seated and locking mechanisms are engaged. Apply dielectric grease to connector seals if specified. Verify orange safety clips or locks are in place.
    ⚠Improper connection of high-voltage cables can cause arcing, connector damage, or charging system failure.
14. 14

    Reconnect low-voltage wiring
    Reconnect the charge port signal harness connector and lock actuator connector. Ensure all connectors are fully seated and locking tabs are engaged. Verify wire routing matches original configuration and no wires are pinched or stressed.
15. 15

    Reinstall interior trim and charge port door
    Reinstall interior side panel using original fasteners and push clips. Replace any damaged clips. From exterior, reinstall charge port door assembly, reconnect door light connector if equipped, and secure with Torx screws. Verify door opens and closes smoothly and latches properly.

Reassembly

1. Verify all fasteners are tightened and no tools or parts are left in work area
2. Confirm all high-voltage connections are secure and properly locked
3. Check that charge port door operates smoothly and seals properly when closed
4. If coolant was disconnected, system will need bleeding and level verification after HV system is re-energized

Verification

• With high-voltage gloves on, reinstall the high-voltage service disconnect plug and lock in place
• Remove lockout/tagout device
• Reinstall 12V service disconnect in front trunk
• Power on vehicle and verify no high-voltage system fault codes are present using diagnostic scan tool
• Check charge port lock operation by cycling vehicle lock/unlock
• Verify charge port indicator lights illuminate correctly when port door is opened
• Connect to a DC fast charger and verify successful handshake and charging initialization
• Monitor first 5 minutes of charging for any error messages, unusual sounds, or overheating at port assembly
• Perform visual inspection of charge port area during charging to verify no coolant leaks (if equipped)
• After successful charge session, verify charge port door closes and seals properly
• Clear any temporary fault codes and verify no new codes are present
• If coolant system was opened, verify proper coolant level in reservoir after system has cycled through charging

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