Coolant Outlet

This procedure covers the removal and replacement of the coolant outlet on a 2022 Rivian EDV 500 dual motor electric delivery van, including coolant system draining and refilling.

Warnings

Tools required

Parts

• Coolant outlet housing × 1 — Use OEM specification
• Coolant outlet gasket or O-ring × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure high voltage system has been properly de-energized and locked out per manufacturer procedures
3. Verify coolant system is completely cool to the touch (allow minimum 2 hours cooling time after operation)
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
5. Remove front underbody panels to access coolant drain points if applicable
6. Place drain pan under coolant outlet and drain valve locations
7. Have replacement coolant ready and inspect for proper specification

Procedure

1. 1

   Drain coolant system
   Locate the coolant drain valve for the affected cooling circuit. Slowly open the drain valve and allow coolant to drain completely into the drain pan. If no drain valve is accessible, carefully loosen the lowest coolant hose connection to drain the system. Capture all coolant for proper disposal or reuse if uncontaminated.
2. 2

   Access coolant outlet
   Remove any engine covers, trim panels, or components obstructing access to the coolant outlet. On the EDV 500, the coolant outlet is typically located on the electric drive unit housing. Document routing of any wiring harnesses or hoses that must be moved aside.
3. 3

   Disconnect electrical connections
   If the coolant outlet has integrated temperature sensors or heating elements, disconnect the electrical connectors. Press the connector release tabs and pull straight back to avoid damaging pins. Inspect connectors for corrosion or damage.
4. 4

   Remove coolant hoses
   Using hose clamp pliers, reposition or remove the hose clamps securing coolant hoses to the outlet. Note the orientation and position of each hose for reinstallation. Gently twist and pull hoses to break any seal with the outlet. If hoses are stuck, use a gentle back-and-forth twisting motion. Inspect hoses for cracks, deterioration, or swelling and replace if necessary.
5. 5

   Remove coolant outlet fasteners
   Remove the bolts or fasteners securing the coolant outlet to the drive unit housing. Keep fasteners organized for reinstallation. Note the location of any ground straps or brackets attached to the outlet fasteners.
6. 6

   Remove coolant outlet
   Carefully pull the coolant outlet away from the mounting surface. If the outlet is stuck, gently tap around the perimeter with a plastic mallet. Do not pry against machined sealing surfaces. Remove and discard the old gasket or O-ring from the mounting surface.
7. 7

   Clean mounting surfaces
   Thoroughly clean the mounting surface on the drive unit housing using a plastic scraper and shop towels. Remove all traces of old gasket material, coolant residue, and debris. Do not use abrasive materials that could damage the sealing surface. Inspect the mounting surface for damage, warping, or corrosion.
8. 8

   Prepare new coolant outlet
   Unpack the new coolant outlet and inspect for damage. Install the new gasket or O-ring onto the outlet, ensuring it is properly seated in its groove. If using a paper gasket, lightly coat both sides with coolant to aid installation. Verify that all ports and passages are clear of debris or protective plugs.
9. 9

   Install coolant outlet
   Position the new coolant outlet onto the mounting surface, aligning all bolt holes and coolant passages. Install fasteners hand-tight initially to ensure proper alignment. Tighten fasteners in a cross-pattern sequence to ensure even gasket compression. Since torque specifications are not available in the database, tighten fasteners gradually and evenly, checking for gasket squeezing and proper seating. Typical specifications for similar components range from 8-12 Nm, but verify with manufacturer documentation.
10. 10

    Reconnect coolant hoses
    Install coolant hoses onto the outlet, ensuring they are fully seated on the barbed fittings. Install new hose clamps or reposition original clamps to the proper location (typically 1/4 inch from the hose end). Tighten clamps securely but avoid overtightening which can damage hoses or fittings.
11. 11

    Reconnect electrical connections
    Reconnect any electrical connectors to temperature sensors or heating elements on the coolant outlet. Ensure connectors click fully into place and locking tabs engage. Apply dielectric grease to connections if specified by manufacturer.
12. 12

    Refill coolant system
    Close the coolant drain valve. Using EV Battery/Motor Coolant, slowly refill the cooling system through the coolant reservoir or designated fill point. Fill gradually to allow air to escape. If available, use a vacuum fill tool to eliminate air pockets. Fill to the proper level marking on the reservoir. The system capacity is approximately 10 quarts, but actual refill amount depends on how much was drained.
13. 13

    Bleed cooling system
    Follow manufacturer bleeding procedure to remove air from the cooling system. This typically involves running the coolant pump while the vehicle is level, opening bleeder valves at high points in the system, and adding coolant as air is purged. Continue until coolant flows from bleed points without bubbles. On electric vehicles, the cooling pump can often be activated through service mode without operating the vehicle.

Reassembly

1. Reinstall any underbody panels or protective covers removed during access
2. Reinstall engine covers and trim panels in reverse order of removal
3. Reconnect 12V auxiliary battery negative terminal
4. Verify all tools and parts have been removed from vehicle
5. Properly dispose of used coolant according to local environmental regulations

Verification

• Check coolant level in reservoir and top off if necessary to proper cold fill mark
• Inspect all connections around the coolant outlet for signs of leaks
• Activate the coolant pump through service mode or by powering the vehicle and observe for leaks while system is under pressure
• Monitor coolant temperature using vehicle diagnostics to ensure proper circulation
• Verify any coolant temperature sensors are reading properly with no fault codes present
• Test drive vehicle and observe coolant temperature remains within normal operating range
• After test drive, allow vehicle to cool and recheck coolant level, topping off as necessary
• Perform a final inspection of the coolant outlet area for any signs of leakage or wetness
• Clear any stored diagnostic trouble codes and verify no new codes appear

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