Complete removal and replacement of the EV chiller unit responsible for cooling the battery and electric drive components on the 2022 Rivian EDV 500.

Warnings

Tools required

Parts

• EV chiller unit assembly × 1 — Use OEM specification
• Chiller mounting bracket gaskets × 2 — Use OEM specification
• Coolant hose O-rings × 4 — Use OEM specification
• Chiller inlet/outlet seals × 2 — Use OEM specification
• Electrical connector seals × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure vehicle has been shut down for at least 2 hours to allow high voltage system to discharge
3. Access the high voltage service disconnect following Rivian safety procedures and remove main battery disconnect
4. Verify high voltage system is de-energized using appropriate high voltage testing equipment
5. Place lockout/tagout device on HV disconnect to prevent accidental reconnection
6. Raise vehicle and support securely on jack stands rated for vehicle weight
7. Remove front underbody shield panels to access chiller unit mounting area
8. Place coolant drain pan under vehicle beneath chiller unit location

Procedure

1. 1

   Recover refrigerant from system
   Connect refrigerant recovery machine to the service ports on the chiller unit. Follow manufacturer instructions to completely recover all refrigerant from the thermal management system. Record the amount recovered for recharge reference.
2. 2

   Disconnect low voltage electrical connections
   Locate and disconnect the low voltage electrical connector from the chiller pump motor. Press the locking tab and pull connector straight back. Disconnect the temperature sensor connectors (2) from the chiller inlet and outlet. Mark connector positions for reinstallation.
3. 3

   Drain coolant from chiller circuit
   Locate the coolant drain valve on the lower chiller inlet line. Attach drain hose to valve and route to drain pan. Open drain valve and allow coolant to drain completely from the chiller circuit. Leave drain valve open during removal.
   ⚠EV coolant may still be warm. Wear protective gloves and eye protection.
4. 4

   Disconnect refrigerant lines
   Using appropriate wrench size, carefully loosen and remove the refrigerant line fittings from the chiller unit inlet and outlet ports. Cap all open refrigerant ports immediately with protective caps to prevent contamination and moisture entry. Inspect O-rings and discard.
5. 5

   Disconnect coolant hoses
   Using hose clamp pliers, release the spring clamps on the coolant inlet and outlet hoses at the chiller unit. Slide clamps back along hoses. Twist and pull hoses to disconnect from chiller fittings. Allow any remaining coolant to drain into pan.
6. 6

   Remove chiller mounting fasteners
   Locate the four mounting bolts securing the chiller unit to the underside mounting bracket. Remove all four bolts and retain for installation. Note the position of any grounding straps or brackets attached to mounting points.
7. 7

   Lower and remove chiller unit
   Support the chiller unit from below with one hand or have an assistant support it. Carefully lower the unit away from the mounting bracket, maneuvering around any nearby components. Remove chiller unit from underneath vehicle. Keep unit level to prevent internal coolant from spilling.
8. 8

   Inspect mounting area and prepare new unit
   Clean the mounting bracket surfaces thoroughly. Inspect all mounting points for damage or corrosion. Check coolant hose condition and replace if cracked or deteriorated. Remove protective caps from new chiller unit and inspect inlet/outlet ports. Install new seals and O-rings on all connection points.
9. 9

   Install new chiller unit
   Position the new chiller unit below the mounting bracket. Carefully raise unit into position, aligning mounting holes with bracket. Thread all four mounting bolts by hand first to ensure proper alignment, then tighten in a cross pattern to secure unit evenly.
10. 10

    Reconnect coolant hoses
    Inspect new O-rings installed on chiller fittings. Push coolant inlet and outlet hoses firmly onto fittings until they seat completely. Slide spring clamps into position over hose connection area, ensuring clamps are properly positioned in the hose groove.
11. 11

    Reconnect refrigerant lines
    Install new O-rings on refrigerant line fittings (lubricate lightly with refrigerant oil). Thread refrigerant line fittings into chiller unit ports by hand to avoid cross-threading. Tighten fittings to proper specification using backup wrench on chiller port to prevent rotation.
12. 12

    Reconnect electrical connections
    Reconnect both temperature sensor connectors to the chiller inlet and outlet sensors. Verify connectors click into locked position. Reconnect the chiller pump motor electrical connector, ensuring locking tab engages fully. Verify all connectors are fully seated.
13. 13

    Refill and bleed coolant system
    Close coolant drain valve. Using vacuum fill method, evacuate air from coolant system and refill with fresh EV Battery/Motor Coolant to proper level. Follow Rivian bleeding procedure to ensure all air is purged from the chiller circuit. Fill coolant reservoir to proper level.
14. 14

    Evacuate and recharge refrigerant system
    Connect vacuum pump to refrigerant service ports. Evacuate system for minimum 45 minutes to remove all air and moisture. Perform vacuum hold test to verify system integrity. Recharge system with proper refrigerant type and quantity per Rivian specifications.

Reassembly

1. Reinstall front underbody shield panels in reverse order of removal
2. Lower vehicle from jack stands
3. Remove lockout/tagout device and reinstall high voltage service disconnect following Rivian procedures
4. Verify all electrical connectors are secure and all fasteners have been reinstalled

Verification

• Start vehicle and allow thermal management system to reach operating temperature
• Monitor coolant level and check for leaks at all chiller connections
• Verify chiller pump operates when commanded by thermal management system
• Check for refrigerant leaks at all connection points using electronic leak detector
• Verify coolant temperature readings are within normal range on vehicle display
• Test drive vehicle and confirm battery temperature remains within acceptable limits during operation
• Perform final inspection of all repair areas for proper installation and no coolant or refrigerant leaks

More procedures for this vehicle