Cooling Fan Assembly

This procedure covers the removal and replacement of the cooling fan assembly on a 2022 Rivian EDV 500, which cools the electric motors and battery thermal management system.

Warnings

Tools required

Parts

• Cooling fan assembly × 1 — Use OEM Rivian specification
• Coolant hose clamps × 2 — Use OEM specification if damaged
• Fan mounting grommets × 4 — Use OEM specification if damaged
• Electrical connector seals × 1 — Use OEM specification if damaged

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off and cooling system cold for minimum 2 hours
3. Open charge port door and verify vehicle is not charging
4. Access the high voltage disconnect location behind front storage compartment
5. Perform high voltage disconnect procedure per Rivian service manual and install lockout tag
6. Disconnect 12V auxiliary battery using 10mm wrench (negative terminal first)
7. Remove front underbody panels to access cooling system components from below
8. Place coolant drain pan under vehicle positioned beneath cooling system drain points

Procedure

1. 1

   Raise and support vehicle
   Lift the front of the vehicle using appropriate lift points located on the battery pack frame rails. Secure with jack stands rated for at least 8,000 lbs. Ensure vehicle is stable before working underneath.
2. 2

   Drain cooling system
   Locate the coolant drain valve on the lower radiator tank. Attach drain hose to valve and route to drain pan. Open drain valve and allow coolant to drain completely. Coolant should be clear and blue-green in color; if contaminated, note for system flush.
3. 3

   Remove front fascia lower section
   Remove Torx fasteners (T25) securing lower front fascia section. There are typically 8 fasteners along the bottom edge. Disconnect any fog light or sensor connectors if equipped. Carefully pull fascia section forward and remove from vehicle.
4. 4

   Access cooling fan assembly
   Locate the cooling fan assembly mounted behind the front cooling stack. Remove the access cover panel by releasing 4 push-pin fasteners. The fan assembly is positioned in front of the motor cooling radiator.
5. 5

   Disconnect electrical connector
   Locate the cooling fan electrical connector on the driver side of the fan shroud. Press the locking tab and pull the connector straight away from the fan motor. Inspect connector terminals for corrosion or damage. If testing fan operation, verify no voltage present using multimeter.
6. 6

   Disconnect coolant hoses
   Using hose clamp pliers, compress and slide back the spring clamps on both coolant hoses connected to the fan shroud. Mark hose positions with tape for reinstallation reference. Twist hoses gently while pulling to remove from fittings. Have rags ready to catch residual coolant.
7. 7

   Remove fan mounting fasteners
   Remove the 4 mounting bolts securing the fan assembly to the cooling stack frame. Bolts are located at each corner of the fan shroud. Support the fan assembly weight while removing the final bolt to prevent it from dropping.
8. 8

   Extract cooling fan assembly
   Carefully tilt the top of the fan assembly toward the front of vehicle while lifting upward. Guide the assembly around any wiring harnesses or brake lines. The assembly weighs approximately 15 lbs. Remove completely from vehicle and place on clean work surface.
9. 9

   Inspect mounting location
   Inspect the mounting grommets in the cooling stack frame for damage or deterioration. Check the radiator fins behind the fan for damage or debris. Remove any leaves, bugs, or debris from the cooling stack. Verify mounting surfaces are clean and free of corrosion.
10. 10

    Prepare new fan assembly
    Unpack new cooling fan assembly and verify correct part number matches vehicle specification. Check that electrical connector matches original. Install new mounting grommets if supplied with replacement fan. Apply thin coat of coolant to hose fitting o-rings.
11. 11

    Install new cooling fan assembly
    Guide the new fan assembly into position, orienting it with electrical connector on driver side. Align mounting holes with grommets in the cooling stack frame. Start all 4 mounting bolts by hand before tightening. Tighten bolts in a cross pattern to ensure even seating.
12. 12

    Reconnect coolant hoses
    Push coolant hoses firmly onto fan shroud fittings until they seat completely against the fitting stops. Slide spring clamps back into position in the grooves on each fitting. Verify hoses are routed correctly per reference marks made during removal.
13. 13

    Reconnect electrical connector
    Align electrical connector with fan motor receptacle and push together until locking tab clicks into place. Gently pull on connector to verify it is fully seated and locked.
14. 14

    Refill cooling system
    Close coolant drain valve. Using a coolant refill funnel with adapter, slowly refill the cooling system with EV Battery/Motor Coolant to the proper level. Fill until coolant reaches the MAX line on the expansion tank. Total system capacity is 10 quarts.
15. 15

    Bleed cooling system
    With coolant filled, locate the bleeder valve on the highest point of the cooling system near the motor inverter. Open bleeder valve until coolant flows without air bubbles, then close. Top off expansion tank to MAX line. This may need to be repeated after initial vehicle operation.

Reassembly

1. Reinstall front fascia lower section and secure with all Torx fasteners
2. Reconnect any fog light or sensor connectors that were disconnected
3. Reinstall front underbody panels and secure all fasteners
4. Lower vehicle from jack stands
5. Reconnect 12V auxiliary battery (positive terminal first, then negative)
6. Remove high voltage lockout tag and reconnect HV system per Rivian service procedure
7. Add additional coolant to expansion tank if level has dropped after bleeding

Verification

• With vehicle in READY mode, observe cooling fan operation through front grille - fan should spin freely without noise or vibration
• Monitor vehicle display for any cooling system fault codes or warnings
• Allow vehicle to reach operating temperature and verify cooling fan activates when thermal management system calls for cooling
• Check for coolant leaks around fan hose connections and mounting area
• Verify coolant level in expansion tank remains at MAX line after test drive
• Test drive vehicle and monitor motor/inverter temperatures using vehicle diagnostics - temperatures should remain within normal range (typically 60-80°C during normal operation)
• Inspect work area under vehicle for any coolant drips 24 hours after repair
• Verify no warning lights or messages appear on instrument cluster related to cooling system

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