Battery Cooling System Service

Complete service of the battery cooling system including coolant replacement, system inspection, and air purging for the 2023 Rivian EDV 500 dual motor electric delivery van.

Warnings

Tools required

Parts

• Battery coolant reservoir cap seal × 1 — Use OEM specification
• Coolant drain plug seal × 1 — Use OEM specification
• Underbody panel clips × 5 — Replacement for damaged clips

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow battery cooling system to cool completely for minimum 2 hours
3. Connect Rivian diagnostic software and verify no active high-voltage faults
4. Document current battery state of charge and thermal management system status
5. Disconnect 12V battery negative terminal and wait 5 minutes
6. Verify high-voltage system is de-energized using insulated voltage testing equipment
7. Install high-voltage service disconnect lockout device
8. Raise vehicle on lift to comfortable working height
9. Remove front underbody panels to access cooling system components
10. Place large drain pan under battery pack drain locations

Procedure

1. 1

   Access battery cooling system reservoir
   Open the front cargo area and locate the battery coolant reservoir on the driver side near the front bulkhead. Remove the plastic cover panel by releasing the retaining clips. Slowly open the reservoir cap to release any residual pressure, using a shop towel to catch any coolant spray.
2. 2

   Drain battery cooling system
   Locate the battery coolant drain valve on the underside of the battery pack near the front center. Connect a drain hose to the valve and route to the drain pan. Open the drain valve and allow coolant to drain completely. This may take 15-20 minutes. Once drained, inspect the coolant for contamination, debris, or discoloration indicating system issues.
3. 3

   Inspect cooling system components
   With coolant drained, inspect all visible cooling lines, hoses, and connections for signs of leakage, damage, or corrosion. Pay particular attention to battery pack cooling plate connections, motor coolant lines, and the chiller unit connections. Check rubber hoses for cracks, softness, or swelling. Inspect the coolant pump and motor for any signs of leakage at the seals.
4. 4

   Remove and inspect coolant filter
   Locate the coolant filter assembly mounted on the battery pack cooling system. Remove the filter housing by turning counterclockwise and pulling straight out. Inspect the old filter element for debris or excessive contamination. Check the filter housing O-ring for damage. Replace filter with new unit, install new O-ring if needed, and reinstall housing by pressing in and turning clockwise until locked.
5. 5

   Check coolant pump operation
   Disconnect the electrical connector from the battery coolant pump. Inspect connector pins for corrosion or damage. Using a digital multimeter, check pump motor winding resistance according to manufacturer specifications (typically 0.5-2.0 ohms). Verify connector is clean and dry before reconnecting.
6. 6

   Install new drain valve seal
   Remove the old drain valve seal from the battery pack drain plug. Clean the sealing surface thoroughly with a lint-free cloth. Install the new drain plug seal and hand-tighten the drain valve. Close the drain valve securely, ensuring proper sealing to prevent leaks.
7. 7

   Prepare vacuum fill equipment
   Connect the coolant vacuum fill tool to the battery coolant reservoir. Ensure all connections are secure and the tool is properly calibrated. Verify that 10 quarts of fresh EV Battery/Motor Coolant is available and at room temperature. Do not use coolant that has been exposed to freezing temperatures or contamination.
8. 8

   Vacuum purge cooling system
   Operate the vacuum fill tool to draw a vacuum on the battery cooling system. Maintain vacuum at 25-28 inches Hg for at least 5 minutes to remove all air from the system. Monitor vacuum gauge for any rapid pressure loss indicating a leak. If vacuum holds steady, proceed to fill. If vacuum drops, locate and repair leak before continuing.
9. 9

   Fill cooling system with new coolant
   With vacuum still applied, open the coolant supply valve on the vacuum fill tool to draw fresh coolant into the system. The vacuum will pull coolant through all cooling passages. Continue filling until coolant reaches the MAX line on the reservoir. Close the supply valve and release vacuum slowly. Top off reservoir to MAX cold fill line if needed.
10. 10

    Reconnect electrical systems
    Install new reservoir cap seal if needed and secure the coolant reservoir cap. Reinstall the reservoir cover panel. Remove the high-voltage service disconnect lockout device. Reconnect the 12V battery negative terminal. Ensure all electrical connections are secure and properly routed.
11. 11

    Prime cooling system with diagnostic software
    Connect Rivian diagnostic software and navigate to the battery thermal management system menu. Initiate the coolant pump priming sequence. This will run the coolant pump at variable speeds to circulate coolant and purge any remaining air. Monitor coolant level in reservoir during this process and add coolant as needed. Priming cycle typically runs 10-15 minutes.
12. 12

    Perform system leak check
    With diagnostic software, activate the battery cooling system to build normal operating pressure. Visually inspect all cooling system connections, hoses, and the battery pack perimeter for any signs of coolant leakage. Use a flashlight and inspection mirror to check hard-to-see areas. Monitor for 10 minutes while system is pressurized. Check coolant level and top off if needed.
13. 13

    Test cooling system function
    Using diagnostic software, command the battery thermal management system through a full operational test. Verify coolant pump operates at multiple speed commands. Monitor coolant temperature sensor readings to ensure they respond appropriately. Check that the chiller engages when commanded. Verify no error codes are generated during testing.
14. 14

    Verify coolant concentration
    Using a coolant refractometer or hydrometer, test a sample of the coolant to verify proper concentration. EV battery coolant should be at the manufacturer-specified concentration, typically 50/50 pre-diluted. Record the reading in the service documentation.

Reassembly

1. Reinstall all underbody panels and secure with new clips where necessary
2. Verify all electrical connectors are fully seated and locked
3. Ensure coolant reservoir is filled to the MAX cold fill line
4. Clear any service mode indicators using diagnostic software
5. Lower vehicle to ground and perform final visual inspection

Verification

• Perform a final check of coolant level with vehicle on level ground - should be at MAX cold fill line
• Connect diagnostic software and verify no active cooling system fault codes
• Start vehicle and allow battery thermal management system to activate - verify normal operation
• Check battery temperature readings are within normal range (typically 15-25°C at startup)
• Verify coolant pump operates smoothly without unusual noise or vibration
• Perform a short test drive and monitor battery temperatures remain stable
• After test drive, recheck coolant level and inspect all connections for leaks
• Document completed service including coolant concentration test results and any findings

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