Replace or repair coolant lines in the EV battery and motor cooling system of the 2022 Rivian EDV 500, ensuring proper thermal management of electric drivetrain components.

Warnings

Tools required

Parts

• EV coolant line assembly × 1 — Use OEM specification - varies by line location
• Coolant line o-rings × 4 — Use OEM specification
• Quick-connect fittings (if damaged) × 2 — Use OEM specification
• Underbody panel clips × 10 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for minimum 2 hours to allow coolant system to cool
3. Open front trunk and disconnect 12V battery negative terminal
4. Use Rivian diagnostic software to verify HV system is de-energized and locked out
5. Raise vehicle on lift or secure on jack stands rated for 7000+ lbs
6. Remove necessary underbody panels to access coolant lines in service area
7. Place drain pan under work area
8. Photograph coolant line routing before disassembly for reference

Procedure

1. 1

   Depressurize cooling system
   Locate the coolant reservoir for the affected cooling loop (battery or motor). Slowly loosen the reservoir cap one full turn to release any residual pressure. Listen for hissing and wait until all pressure is released before fully removing cap. Verify coolant temperature is below 100°F.
2. 2

   Drain coolant from system
   Position drain pan under the coolant drain valve or lowest point in the affected cooling loop. Open drain valve using appropriate socket or use line disconnect tool to remove lower coolant line at connection point. Allow coolant to drain completely into pan. Collect and properly dispose of old coolant according to local regulations.
3. 3

   Remove interfering components
   Identify any components blocking access to the coolant lines requiring service. This may include belly pans, wire harness brackets, or air dam assemblies. Remove fasteners and carefully move components aside, ensuring no strain is placed on electrical connectors or other lines. Label or photograph connections as needed.
4. 4

   Disconnect coolant temperature sensors
   Locate any coolant temperature sensors mounted on the coolant lines being serviced. Press the locking tab and disconnect the electrical connector. Carefully remove sensor from line if integrated into fitting. Note sensor orientation for reinstallation.
5. 5

   Release coolant line mounting clips
   Identify all mounting clips and brackets securing the coolant lines to chassis or body structure. Use trim tools or appropriate sockets to release clips. Note the position and orientation of each clip for proper reinstallation to prevent line vibration or contact with other components.
6. 6

   Disconnect coolant lines at junction points
   Using the line disconnect tool, press the release collar on quick-connect fittings while pulling the line straight out. For threaded connections, use appropriate wrench to loosen fittings. Work methodically from one end of the line to the other. Catch any residual coolant with shop towels or drain pan.
7. 7

   Remove damaged coolant lines
   Once all connections are released, carefully maneuver the coolant line assembly out of the vehicle. Take care not to snag the line on sharp edges or HV cables. Inspect the removed line for damage patterns to identify root cause of failure. Check routing path for potential contact or chafe points.
8. 8

   Prepare new coolant lines
   Unpack new coolant line assembly and verify part number matches vehicle specification. Inspect all fittings and o-rings for damage from shipping. Apply thin coat of fresh EV coolant to all o-rings to aid installation. Compare new line to old line to confirm configuration matches.
9. 9

   Install new coolant lines
   Route new coolant line assembly through vehicle following original path or improved routing if chafe point was identified. Ensure adequate clearance from HV cables, moving components, and sharp edges. Do not force or kink lines during installation. Verify line sits naturally in mounting positions.
10. 10

    Connect coolant line fittings
    Install coolant lines at all connection points. For quick-connect fittings, push line firmly into fitting until an audible click is heard, then pull back to verify lock engagement. For threaded connections, hand-tighten first, then use wrench to snug. Do not overtighten as this can damage o-rings or aluminum fittings.
11. 11

    Secure coolant lines with mounting clips
    Install all mounting clips and brackets in their original positions. Ensure clips hold lines securely without crushing or deforming them. Verify minimum 1-inch clearance from all HV cables and moving components. Check that lines do not contact sharp edges or potential wear points.
12. 12

    Reinstall coolant temperature sensors
    Install coolant temperature sensors into new coolant lines in proper orientation. If sensors have o-ring seals, ensure they are properly seated. Connect electrical connectors and verify locking tabs engage fully. Check that sensor wiring has adequate slack and is not strained.
13. 13

    Fill cooling system with fresh coolant
    Fill coolant reservoir with fresh Rivian-specified EV Battery/Motor Coolant to the cold fill line. Do not overfill. If system has a bleed valve, open valve and continue filling until solid coolant stream flows from bleed port, then close valve. Total system capacity is approximately 10 quarts.
14. 14

    Bleed air from cooling system
    With reservoir cap off, reconnect 12V battery and use Rivian diagnostic software to activate coolant pump in service mode. Run pump for 30-second intervals, monitoring coolant level and adding as needed. Watch for air bubbles in reservoir and continue until flow is bubble-free. Turn off pump and install reservoir cap.
15. 15

    Pressure test cooling system
    Using coolant pressure test kit adapted to Rivian reservoir, pressurize system to 15 PSI. Hold pressure for 5 minutes and monitor gauge. Pressure should not drop more than 1 PSI. Inspect all connections, joints, and line routing for leaks. Address any leaks found before proceeding.

Reassembly

1. Reinstall all underbody panels and fasteners removed during access
2. Verify all clips and fasteners are properly secured
3. Double-check clearance between coolant lines and HV cables
4. Ensure no tools or parts were left in work area
5. Lower vehicle to ground

Verification

• Reconnect 12V battery if disconnected for testing
• Use Rivian diagnostic software to clear any stored fault codes related to cooling system
• Power on vehicle and monitor cooling system status through vehicle display
• Allow vehicle to complete ready-to-drive state and run coolant pump through normal operation
• Check coolant reservoir level with system warm - add coolant if needed to bring to hot fill line
• Inspect all coolant line connections for leaks with system at operating temperature
• Perform test drive to verify proper cooling system operation under load
• Re-check coolant level after test drive and top off if necessary
• Verify no warning lights or cooling system fault codes are present
• Document repair with photos and update vehicle service records

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