This procedure covers the removal and replacement of the radiator on a 2022 Rivian EDV 500, including coolant drainage, component disconnection, and refilling of the EV battery/motor cooling system.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Radiator drain plug O-ring × 1 — Replace if damaged
• Upper radiator hose clamp × 1 — Replace if corroded
• Lower radiator hose clamp × 1 — Replace if corroded
• EV Battery/Motor Coolant × 10 — Use Rivian-approved coolant only

Fluids

• coolant — 10 qt

Preparation

1. Park vehicle on level surface and allow cooling system to cool for at least 2 hours
2. Disconnect 12V battery negative terminal and wait 5 minutes
3. Remove front underbody panel to access drain plug and lower radiator area
4. Place drain pan under radiator drain petcock location
5. Document all electrical connector orientations with photos before disconnection

Procedure

1. 1

   Drain cooling system
   Slowly open the radiator drain petcock at the bottom of the radiator. Allow coolant to drain completely into drain pan. Once drained, close petcock hand-tight to plastic thread specification.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove front fascia lower section
   Remove plastic push clips securing lower front fascia. Carefully pull lower fascia section forward to access radiator mounting area. Set aside fascia in protected area to avoid damage.
3. 3

   Disconnect electrical connections
   Locate and disconnect the cooling fan electrical connector on the left side of radiator assembly. Press release tab and pull connector straight back. If equipped, disconnect coolant temperature sensor connector on radiator outlet.
4. 4

   Remove upper radiator hose
   Using hose clamp pliers, reposition the upper radiator hose clamp away from radiator neck. Twist hose gently to break seal, then pull hose off radiator inlet. Be prepared for residual coolant spillage.
5. 5

   Remove lower radiator hose
   Access lower radiator hose from underneath vehicle. Reposition lower hose clamp away from radiator outlet using hose clamp pliers. Twist and remove hose from radiator. Allow any remaining coolant to drain into pan.
6. 6

   Disconnect transmission cooler lines (if equipped)
   If vehicle has transmission cooler integration, use 19mm flare nut wrench to disconnect cooler lines from radiator side tanks. Cap or plug lines immediately to prevent contamination. Catch any residual fluid.
   ℹ️EDV 500 typically does not use integrated transmission cooler, but verify your specific configuration.
7. 7

   Remove radiator mounting bolts
   Locate the radiator mounting bolts at top corners and bottom supports of radiator assembly. Using 10mm socket, remove all mounting bolts. Note that these secure to plastic mounting brackets - do not force or overtighten during reinstallation.
8. 8

   Remove radiator assembly
   Carefully lift radiator assembly upward and out of engine bay, tilting slightly to clear cooling fan assembly and front cross member. Have assistant support cooling fan if it remains attached. Avoid damaging cooling fins or mounting tabs.
   ⚠Radiator is lightweight but awkward. Avoid contact with high voltage orange cables in vicinity.
9. 9

   Prepare new radiator
   Inspect new radiator for shipping damage. Install new drain plug O-ring if provided. Verify all mounting tabs are intact and cooling fan mounts properly if transferring from old unit. Compare old and new radiators to ensure correct fitment.
10. 10

    Install new radiator
    Carefully lower new radiator into position, aligning mounting tabs with chassis brackets and ensuring cooling fan clears all surrounding components. Verify radiator sits flush against all mounting points before installing bolts.
11. 11

    Install radiator mounting bolts
    Thread all radiator mounting bolts by hand first to ensure proper alignment. Using torque wrench and 10mm socket, tighten mounting bolts to specification in a cross pattern. Do not overtighten as mounting brackets are plastic.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect coolant hoses
    Install lower radiator hose onto radiator outlet, ensuring hose is fully seated. Position new clamp and tighten to specification. Repeat for upper radiator hose. Verify both hoses are properly seated before tightening clamps.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
13. 13

    Reconnect transmission cooler lines (if equipped)
    If removed, reconnect transmission cooler lines to radiator using new sealing washers. Tighten fittings to specification using flare nut wrench. Do not overtighten aluminum fittings.
    Torque spec

    Transmission Cooler Lines25 Nm (18 lb-ft)
14. 14

    Refill cooling system
    Using coolant funnel, slowly fill cooling system with Rivian-approved EV battery/motor coolant through radiator cap opening or expansion tank. Fill to approximately 10 quarts total capacity. Allow air to escape as system fills. Do not overfill.
    ⚠Fill slowly to avoid air pockets. EV cooling systems require proper bleeding for optimal battery thermal management.
15. 15

    Bleed cooling system
    With radiator cap still off, reconnect 12V battery. Start vehicle and allow to run until cooling fan cycles on. Monitor coolant level and add as needed while system purges air. Once fan cycles and level stabilizes, install radiator cap. Check for leaks around all connections.
    ⚠Monitor battery and motor temperatures on vehicle display during bleeding process. Shut down if temperatures exceed normal range.

Reassembly

1. Reinstall front fascia lower section and secure all push clips
2. Reinstall front underbody panel
3. Reconnect all electrical connections verified during preparation
4. Double-check all hose clamps and drain petcock are secure
5. Verify cooling fan operates correctly by running vehicle to operating temperature

Verification

• Start vehicle and verify no coolant leaks are present at radiator connections, hoses, or drain plug
• Monitor coolant temperature on vehicle display - should reach and maintain normal operating range
• Verify cooling fan cycles on and off automatically as temperature fluctuates
• Check coolant level after initial test drive and top off if necessary
• Inspect ground under vehicle for any coolant drips after 24 hours of operation
• Verify no warning lights or cooling system faults displayed on instrument cluster

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