This procedure covers the removal and replacement of the EV cooling system radiator on a 2022 Rivian EDV 500, including coolant drain, radiator removal, and system refill.

Warnings

Tools required

Parts

• EV cooling system radiator × 1 — Use OEM specification
• Radiator mounting grommets × 4 — Use OEM specification
• Coolant hose O-rings (if applicable) × 4 — Use OEM specification
• Front bumper cover clips × 10 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off for at least 2 hours to allow cooling system to depressurize and cool
3. Disconnect 12V battery negative terminal and secure away from battery post
4. Wait minimum 5 minutes for high-voltage system capacitors to discharge
5. Remove front floor panel or access covers to access coolant drain points
6. Place coolant drain pan under vehicle at front coolant drain location
7. Take photos of all hose routing, electrical connections, and component positions for reference during reassembly

Procedure

1. 1

   Drain cooling system
   Locate the coolant drain valve at the bottom of the radiator or lower coolant hose connection. Slowly open the drain valve and allow coolant to drain completely into the drain pan. If no drain valve is present, carefully disconnect the lower radiator hose at the radiator connection using the appropriate quick disconnect tool. Ensure all coolant is collected for proper disposal.
2. 2

   Remove front fascia and grille assembly
   Remove the front bumper cover by removing all T25 Torx screws along the top edge and wheel well areas. Disconnect any electrical connectors for sensors or lighting in the front fascia. Carefully remove panel clips using the panel removal tool. With assistance, remove the front bumper cover and set aside on a protected surface. Remove the grille assembly by removing T30 Torx fasteners and releasing retaining clips.
3. 3

   Remove active grille shutter system (if equipped)
   Disconnect the electrical connector from the active grille shutter motor. Remove the mounting bolts securing the active grille shutter assembly using a 10mm socket. Carefully remove the assembly and set aside, noting the orientation and any guide pins for reinstallation.
4. 4

   Disconnect cooling fan assembly
   Disconnect the electrical connector(s) from the cooling fan motor(s). Remove the mounting bolts securing the fan shroud assembly to the radiator using a 10mm socket. Carefully lift the fan assembly straight up and out of the radiator mounting brackets. Set aside the fan assembly in a safe location.
5. 5

   Disconnect coolant hoses from radiator
   Identify the upper and lower radiator coolant hoses. Using the appropriate quick disconnect tool, release the quick connect fittings at the radiator. If equipped with threaded connections, use a 13mm wrench to loosen hose clamps and carefully twist hoses to break seal before removing. Have a drain pan ready to catch residual coolant. Cap or plug open hose ends to prevent contamination.
6. 6

   Disconnect auxiliary coolant lines
   Locate any auxiliary coolant lines connected to the radiator, including lines to the battery thermal management system or motor cooling loops. Using quick disconnect tools, carefully release each connection. Note and document the routing and connection points of each line with photos. Cap all open connections to prevent contamination.
7. 7

   Remove radiator mounting hardware
   Locate the radiator mounting brackets on both sides of the radiator. Remove the upper mounting bolts or brackets using a 10mm or 13mm socket. Remove any lower mounting bolts or support brackets. Note the position of any spacers or alignment guides for reinstallation.
8. 8

   Remove radiator from vehicle
   Carefully lift the radiator straight up and out of the engine bay, ensuring no hoses or wiring are still connected. The radiator may have lower alignment tabs that need to be cleared from mounting points. Tilt as necessary to clear any obstructions, being careful not to damage fins or mounting points. Inspect the removed radiator for damage and verify replacement part matches.
9. 9

   Install new radiator
   Inspect new radiator and install new mounting grommets in radiator brackets if supplied. Carefully lower the new radiator into position, aligning lower mounting tabs with frame brackets. Ensure radiator is fully seated in all mounting points. Install upper mounting brackets and bolts, tightening to secure the radiator but do not fully torque at this time.
10. 10

    Reconnect auxiliary coolant lines
    Using your reference photos, reconnect all auxiliary coolant lines to the radiator in the correct sequence. If using quick connect fittings, ensure each fitting clicks and is fully seated. Install new O-rings if supplied with the radiator. Verify each connection is secure by pulling gently on each line.
11. 11

    Reconnect main coolant hoses
    Remove caps from coolant hoses. Install new O-rings on quick connect fittings if applicable. Connect upper and lower radiator hoses, ensuring quick connect fittings fully engage with an audible click. If using clamp-style connections, position hoses fully onto radiator necks and tighten clamps securely with a 13mm wrench.
12. 12

    Reinstall cooling fan assembly
    Carefully position the cooling fan shroud assembly back onto the radiator, aligning mounting brackets with radiator mounting points. Install and tighten mounting bolts using a 10mm socket. Reconnect all electrical connectors to fan motor(s), ensuring connectors are fully seated and locked.
13. 13

    Final mounting bolt torque and verification
    Using a torque wrench, torque all radiator mounting bolts to proper specification per service manual. Verify all coolant connections are secure. Reinstall active grille shutter system if equipped, connecting electrical connector and securing mounting bolts. Double-check that no tools or parts remain in the engine bay.
14. 14

    Refill cooling system
    Using the specified EV Battery/Motor Coolant, refill the cooling system through the designated fill point. Fill slowly to minimize air pockets, adding approximately 10 quarts or until coolant reaches the full mark on the reservoir. Do not overfill. Leave reservoir cap loose initially to allow air to escape during bleeding process.
15. 15

    Bleed cooling system and test
    Reconnect 12V battery. Using Rivian diagnostic software or compatible scan tool, activate the cooling system bleed procedure. This will cycle the coolant pumps to purge air from the system. Monitor coolant level in reservoir and add coolant as needed during the bleeding process. Run the bleed cycle until no air bubbles are visible. Once complete, top off coolant to proper level and secure reservoir cap. Check all connections for leaks.

Reassembly

1. Reinstall front grille assembly, ensuring all mounting clips and fasteners are secure
2. Reinstall front bumper cover, connecting all electrical connectors for sensors and lighting
3. Install all bumper cover fasteners and clips, ensuring proper alignment
4. Verify all panels are properly seated and gaps are even

Verification

• Start vehicle and allow thermal management system to reach operating temperature
• Using diagnostic software, verify coolant temperature sensors are reading normally and within expected range
• Check for coolant leaks at all radiator connections, hoses, and mounting points
• Verify cooling fans activate when coolant temperature reaches threshold
• Check coolant level in reservoir after test drive and top off if necessary
• Monitor vehicle for proper battery thermal management during charging cycle
• Clear any diagnostic trouble codes related to cooling system if they were set during repair
• Verify no warning lights or messages are displayed on instrument cluster

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