Battery Cooling System Service

Service the battery thermal management cooling system on the 2022 Rivian EDV 500, including coolant drain, flush, component inspection, and refill with EV-specific coolant.

Warnings

Tools required

Parts

• Battery coolant reservoir cap × 1 — Use OEM specification
• Coolant drain plug seal × 1 — Use OEM specification
• Battery cooling system O-rings × 1 — Use OEM specification
• Underbody panel fasteners × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure battery pack has cooled to ambient temperature (wait minimum 2 hours after driving)
3. Disconnect 12V auxiliary battery negative terminal
4. Access high-voltage service disconnect located under rear seat
5. Remove high-voltage service disconnect and install lockout device
6. Wait 5 minutes for high-voltage capacitors to discharge
7. Using digital multimeter, verify zero voltage at high-voltage terminals
8. Don high-voltage insulated gloves rated for minimum 450V DC
9. Connect Rivian diagnostic tool and document any stored fault codes
10. Raise vehicle on lift or support securely on jack stands
11. Remove front and rear underbody panels to access cooling system components

Procedure

1. 1

   Locate and access battery cooling system components
   Identify the battery coolant reservoir in the front compartment, battery pack cooling lines running along underbody, coolant pump mounted to battery pack, and radiator in front cooling module. Inspect all visible components for signs of leakage, damage, or corrosion before proceeding.
2. 2

   Drain battery cooling system
   Place drain pan under battery pack drain point located at lowest point of cooling circuit on driver side of pack. Remove drain plug carefully and allow coolant to drain completely. This may take 15-20 minutes. Once drained, inspect coolant condition for contamination, discoloration, or debris.
3. 3

   Remove coolant reservoir and inspect
   Disconnect electrical connector from coolant level sensor on reservoir. Disconnect inlet and outlet hoses from reservoir, noting orientation. Remove reservoir mounting fasteners and lift reservoir out. Inspect reservoir interior for sediment or debris. Clean if reusable or replace if contaminated.
4. 4

   Access and inspect battery coolant pump
   Locate coolant pump attached to battery pack underside. Disconnect electrical connector from pump. Inspect pump housing for leaks or cracks. Check pump impeller for damage by attempting to rotate shaft by hand (should rotate with slight resistance). Replace pump if seized, leaking, or damaged.
5. 5

   Inspect cooling lines and connections
   Trace all cooling lines from battery pack to front radiator module. Inspect quick-connect fittings, rubber hoses, and metal hard lines for cracks, wear, or damage. Check for evidence of coolant weeping at connection points. Pay special attention to areas where lines pass through chassis mounting points for chafing damage.
6. 6

   Inspect battery pack cooling channels
   Using diagnostic tool, command battery coolant pump to run (with system still drained) and listen for abnormal noises indicating internal blockage. Inspect visible cooling plate surfaces at battery pack edges for corrosion or damage. Use borescope if available to inspect internal cooling channels through drain port.
7. 7

   Flush cooling system
   Connect coolant flush equipment to cooling system. Use only EV-compatible flushing solution or distilled water. Flush system according to equipment manufacturer instructions until discharge runs clear. Pay attention to flush fluid color and clarity to determine when system is clean. Drain flush solution completely.
8. 8

   Replace seals and reassemble components
   Install new drain plug seal and reinstall drain plug. Replace all O-rings on coolant line connections with new EV-compatible O-rings. Reinstall coolant pump if removed, ensuring proper seating and connector engagement. Reinstall coolant reservoir with new cap if needed, reconnecting all hoses and electrical connector.
9. 9

   Vacuum fill cooling system
   Connect vacuum fill tool to coolant reservoir. Draw vacuum on system to -25 inHg and hold for 5 minutes to check for leaks (vacuum should not drop more than 2 inHg). Once leak test passes, use vacuum fill method to draw fresh EV battery coolant into system. Fill to proper level mark on reservoir.
10. 10

    Purge air from cooling system
    Using diagnostic tool, command battery thermal management system into purge mode. This will cycle coolant pump at varying speeds to purge trapped air. Monitor coolant level in reservoir and add coolant as needed. Continue purge cycle for 10-15 minutes or until no air bubbles visible in reservoir.
11. 11

    Pressure test cooling system
    Install cooling system pressure tester to reservoir. Pressurize system to 15 PSI and hold for 5 minutes. Inspect all connections, hoses, and components for leaks. System should not lose more than 1 PSI during test. If leaks detected, depressurize, repair, and retest.
12. 12

    Reinstall underbody panels and lower vehicle
    Clean and inspect all underbody panels before reinstallation. Install panels with new fasteners as needed, ensuring proper alignment and secure attachment. Verify no tools or parts left in underbody area. Lower vehicle to ground.
13. 13

    Restore high-voltage system
    Remove lockout device from high-voltage service disconnect. Reinstall high-voltage service disconnect, ensuring proper seating and locking. Reinstall rear seat access panel. Reconnect 12V auxiliary battery negative terminal.
14. 14

    Initialize and test cooling system operation
    Using diagnostic tool, clear any stored fault codes. Start vehicle and allow thermal management system to initialize. Monitor coolant temperature, flow rate, and pump operation through diagnostic tool. Verify cooling system reaches normal operating parameters without faults. Check for proper coolant circulation and no leaks.

Reassembly

1. Torque all fasteners to manufacturer specifications when available
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify coolant level is at proper mark on reservoir after system reaches operating temperature
4. Double-check that high-voltage service disconnect is properly installed and locked
5. Confirm all underbody panels are securely fastened and aligned properly

Verification

• Using diagnostic scan tool, verify no cooling system fault codes present
• Confirm coolant level stable at proper mark with system at operating temperature
• Verify battery pack temperature regulation functioning properly through diagnostic data
• Check for coolant leaks at all connections and components with system pressurized
• Test drive vehicle and monitor battery thermal management system operation
• Verify coolant pump operates smoothly without unusual noise or vibration
• Confirm battery temperature remains within normal range during operation
• Recheck coolant level after test drive and top off if necessary
• Document final coolant level, system test results, and any fault codes in service records

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