Radiator Removal and Service

This procedure covers the removal and service of the radiator (coolant heat exchanger) for the electric drive motors and battery thermal management system on the 2022 Rivian EDV 500 dual motor AWD variant.

Warnings

Tools required

Parts

• Radiator assembly with integrated fans × 1 — Use OEM specification
• Coolant line O-rings and seals kit × 1 — Use OEM specification
• Front fascia push clips × 10 — Use OEM specification
• Underbody shield clips × 8 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Using Rivian diagnostic software, command the vehicle to thermal management service mode to stop coolant circulation pumps
3. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system capacitor discharge
4. Verify HV battery disconnect status using diagnostic software - status must show 'Disconnected'
5. Raise vehicle to comfortable working height and secure on jack stands at all four jack points
6. Remove front wheels to access underbody panels and wheel well liners
7. Allow coolant system to cool to ambient temperature (minimum 2 hours after last drive cycle)
8. Place coolant drain pan beneath front center of vehicle below radiator location
9. Document or photograph all electrical connections for accurate reassembly

Procedure

1. 1

   Remove front fascia and underbody panels
   Remove front fascia lower section by releasing 8 push clips along bottom edge and 4 Torx T30 screws in wheel well areas. Carefully pull fascia forward to disengage upper clips. Remove front underbody shield by removing 10 T40 Torx bolts. Set aside panels in protected area to avoid damage.
2. 2

   Access radiator assembly area
   Remove front wheel well liner extensions on both sides using T20 Torx screws (6 per side). Disconnect ambient air temperature sensor connector located on driver side of radiator support. Remove charge port cooling duct if equipped by releasing 2 clips at top of radiator support.
3. 3

   Disconnect radiator electrical connections
   Locate the dual cooling fan electrical connector on passenger side of radiator assembly. Press release tab and disconnect main fan power connector. Disconnect coolant temperature sensor connector on driver side radiator tank. Label connections if not already documented.
4. 4

   Drain primary coolant circuit
   Locate radiator drain petcock on bottom driver side radiator tank. Slowly open drain valve and allow coolant to drain into collection pan. This will drain approximately 6-8 quarts. Once flow stops, close petcock. Move drain pan to capture additional coolant from line disconnections.
5. 5

   Disconnect upper coolant lines
   Using appropriate quick-disconnect tool, release upper coolant supply line from radiator inlet (driver side upper tank). Press tool onto fitting, push line toward radiator, then pull line away while holding tool in place. Expect residual coolant spillage. Repeat for upper coolant return line on passenger side upper tank. Cap open ports with clean shop towels.
6. 6

   Disconnect lower coolant lines
   From below vehicle, locate and disconnect lower coolant inlet and outlet lines using same quick-disconnect technique. These connections are at bottom of radiator tanks. The driver side connects to battery cooling circuit, passenger side to motor cooling circuit. Allow residual coolant to drain.
7. 7

   Remove radiator mounting hardware
   Remove upper radiator mounting brackets by removing two 10mm bolts per side securing brackets to radiator support frame. Remove lower radiator mounting cushions by removing single 10mm bolt from each lower mount point (2 total). Support radiator weight while removing final fasteners.
8. 8

   Extract radiator assembly
   Carefully tilt top of radiator toward rear of vehicle to clear upper support frame. Lift radiator assembly upward and forward out of vehicle, taking care not to damage cooling fins on surrounding components. Integrated fans remain attached to radiator. Guide assembly through front opening, protecting fragile aluminum fins and plastic tanks.
9. 9

   Inspect and service radiator
   With radiator removed, inspect for external damage, fin damage, tank cracks, and coolant leaks. Check radiator cap and pressure valve operation. If servicing rather than replacing, flush radiator with clean water, pressure test to 15 PSI for 10 minutes, and verify cooling fan motor operation using 12V power supply. Inspect and replace all coolant line O-rings in seal kit.
10. 10

    Install serviced or replacement radiator
    Install new O-rings on all four coolant ports using light coat of EV coolant as lubricant. Guide radiator assembly into position through front opening, tilting top rearward to clear support frame. Seat lower mounting cushions first, then align upper mounting brackets. Install all mounting hardware hand-tight initially.
11. 11

    Connect coolant lines
    Connect all four coolant quick-connect fittings in reverse order of removal. Push each line firmly onto radiator port until audible click is heard and visual indicator (if present) shows proper engagement. Gently tug each line to verify secure connection. Ensure no cross-threading or binding.
12. 12

    Reconnect electrical connections
    Reconnect coolant temperature sensor connector on driver side tank. Reconnect dual cooling fan main power connector on passenger side - ensure positive lock engagement. Reconnect ambient temperature sensor to radiator support. Verify all connectors are fully seated with no exposed terminals.
13. 13

    Refill coolant system
    Using EV Battery/Motor Coolant only, refill system through coolant reservoir to MAX line. System capacity is approximately 10 quarts total. Do not overfill. Close reservoir cap. Using Rivian diagnostic software, command cooling system purge cycle to remove air from system. Monitor coolant level and add as needed during purge cycle.
14. 14

    Verify system operation and check for leaks
    With drain pan still in place, reconnect 12V battery. Using diagnostic software, activate thermal management system and command cooling fans to run at various speeds. Verify both fans operate correctly. Inspect all coolant connections for leaks while system is pressurized. Allow system to reach operating temperature (approximately 10-minute run cycle). Recheck coolant level and top off if needed.
15. 15

    Reinstall underbody panels and fascia
    Reinstall front underbody shield using all T40 Torx bolts. Reinstall wheel well liner extensions using T20 screws. Reinstall front fascia lower section, ensuring all clips engage properly and Torx screws are secured. Reinstall front wheels. Lower vehicle from jack stands. Clear all diagnostic codes and exit service mode using Rivian diagnostic software.

Reassembly

1. Tighten all radiator mounting hardware to secure radiator without over-compressing rubber isolation mounts
2. Ensure all quick-disconnect coolant fittings are fully engaged with audible click confirmation
3. Verify all electrical connectors have positive lock engagement and weather seals are properly seated
4. Replace any broken push clips or fasteners with new OEM parts to maintain proper panel fit
5. Confirm coolant level is at MAX line on reservoir after final pressure cycle

Verification

• Using Rivian diagnostic software, verify no active coolant system fault codes are present
• Confirm coolant temperature readings from both battery and motor cooling circuits are within normal range (typically 20-35°C at idle)
• Verify both cooling fans activate during commanded test sequence at low, medium, and high speeds
• Perform visual inspection under vehicle for any coolant leaks at radiator connections after 15-minute test run
• Check coolant level after vehicle reaches operating temperature - level should remain at MAX line
• Test drive vehicle and monitor thermal management system performance using diagnostic software - coolant temperatures should remain stable under normal driving conditions
• Re-inspect all connections 24 hours after repair and after first 50 miles of driving

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