This procedure covers the removal and replacement of the battery thermal management module, which circulates coolant to regulate battery pack temperature in the 2023 Rivian EDV 500.

Warnings

Tools required

Parts

• Battery thermal management module × 1 — Use OEM specification
• Thermal management module mounting gasket/seal × 1 — Use OEM specification
• Coolant hose O-rings (various sizes) × 1 — Use OEM specification
• High voltage connector seals × 1 — Use OEM specification
• Underbody panel fasteners × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure battery state of charge is below 30% if possible to minimize stored high voltage energy
3. Access Rivian service mode through vehicle interface to prepare for high voltage disconnect
4. Place high voltage service disconnect tags/locks on steering wheel
5. Chock all four wheels securely
6. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
7. Put on high voltage safety gloves and ensure insulated tools are available

Procedure

1. 1

   Isolate high voltage system
   Remove lower center console access panel to access high voltage service disconnect. Using high voltage safety gloves, rotate the service disconnect lever counterclockwise 90 degrees and remove the disconnect plug. Store disconnect plug in a secure location away from vehicle. Use high voltage meter to verify zero voltage at battery pack terminals. Wait minimum 15 minutes for capacitor discharge.
2. 2

   Raise vehicle and remove underbody panels
   Raise vehicle on lift to working height. Remove center underbody panels using panel removal tools, exposing battery pack and thermal management components. Remove fasteners in sequence from rear to front to prevent panel binding. Label and store all fasteners by location.
3. 3

   Drain battery cooling system
   Locate battery thermal system drain valve on lower side of battery pack. Place drain pan underneath (minimum 15 quart capacity). Open drain valve and allow coolant to drain completely. This may take 15-20 minutes. Capture and measure drained coolant quantity to verify system capacity. Inspect drained coolant for contamination or debris.
4. 4

   Disconnect coolant lines from thermal management module
   Locate thermal management module mounted on underside of battery pack, approximately center position. Using appropriate socket, loosen coolant line connection nuts at module inlet and outlet ports. Have rags ready to capture residual coolant. Mark coolant lines for correct reassembly orientation (inlet vs outlet). Cap open coolant ports immediately to prevent contamination.
5. 5

   Disconnect electrical connections
   Identify thermal management module electrical connectors (pump power, temperature sensors, flow sensor). Press connector lock tabs and carefully disconnect each connector. Note connector positions and routing. Inspect connector pins for corrosion or damage. Use electrical contact cleaner if needed.
6. 6

   Remove thermal management module mounting hardware
   Locate module mounting bolts (typically 4-6 bolts around perimeter). Remove mounting bolts in diagonal sequence to prevent module distortion. Support module weight during removal of final bolts. Note the location of any ground straps or brackets attached to mounting points.
7. 7

   Remove thermal management module
   Carefully lower thermal management module from battery pack mounting location. Module weighs approximately 15-20 lbs. Guide module past any surrounding components, paying attention to clearance with battery pack frame rails. Place module on clean work surface and inspect mounting area.
8. 8

   Clean mounting surface and inspect battery pack interface
   Clean thermal management module mounting surface on battery pack using lint-free cloths and approved cleaner. Remove all old gasket material and coolant residue. Inspect battery pack thermal interface surface for damage, corrosion, or coolant leaks. Check mounting bolt threads for damage. Verify battery pack thermal sensors are intact and properly positioned.
9. 9

   Prepare new thermal management module
   Remove new thermal management module from packaging and verify part number matches application. Install new mounting gasket/seal on module according to orientation marks. Lubricate new coolant O-rings with small amount of EV coolant and install in coolant port grooves. Verify pump impeller rotates freely by hand. Check all electrical connector seals are properly seated.
10. 10

    Install new thermal management module
    Carefully position new thermal management module into battery pack mounting location. Align coolant ports with battery pack coolant passages. Ensure gasket remains properly positioned during installation. Start all mounting bolts by hand to ensure proper thread engagement before tightening. Tighten mounting bolts in diagonal cross-pattern sequence to ensure even gasket compression and proper thermal contact.
11. 11

    Reconnect electrical connections
    Reconnect all electrical connectors to thermal management module in reverse order of removal. Ensure each connector locks with audible click. Route wiring harnesses to original positions and secure with any clips or ties. Verify no wiring is pinched or stressed. Double-check all connections are fully seated.
12. 12

    Reconnect coolant lines
    Remove protective caps from coolant ports. Verify O-rings are in place and not damaged. Connect coolant inlet and outlet lines according to marks made during disassembly. Tighten coolant line connection nuts to secure connections, ensuring lines are not twisted or kinked. Verify proper routing with no interference.
13. 13

    Refill and bleed battery cooling system
    Close battery cooling system drain valve. Fill system with new EV Battery/Motor Coolant through fill port. Use vacuum fill tool if available to eliminate air pockets. Fill to proper level (approximately 10 quarts total system capacity). With coolant reservoir cap removed, cycle ignition to run position (high voltage still disconnected) to activate coolant pump briefly. Add additional coolant as level drops. Repeat until no air bubbles appear and level stabilizes.
14. 14

    Reinstall underbody panels and lower vehicle
    Reinstall center underbody panels in reverse order of removal (front to rear). Ensure all panel alignment tabs are properly engaged. Install all fasteners and secure panels. Verify no tools or parts are left in underbody area. Lower vehicle to ground level.
15. 15

    Reconnect high voltage system and restore vehicle
    With high voltage safety gloves on, reinstall high voltage service disconnect plug. Rotate disconnect lever clockwise 90 degrees to locked position. Verify disconnect is fully seated and secured. Reinstall lower console access panel. Reconnect 12V auxiliary battery negative terminal. Remove service disconnect tags from steering wheel.

Reassembly

1. All electrical connections must be fully seated with audible clicks and proper locking mechanism engagement
2. Coolant system must be properly filled and bled with no air pockets to prevent thermal management issues
3. Underbody panels must be correctly aligned and secured to maintain vehicle aerodynamics and component protection
4. High voltage service disconnect must be fully engaged and verified before returning vehicle to service

Verification

• Using Rivian diagnostic scanner, clear high voltage disconnect event codes and perform system initialization
• Activate battery thermal management system through scanner and verify coolant pump operation (listen for pump motor sound)
• Monitor coolant temperature sensors through scanner to confirm proper readings and no fault codes
• Check for coolant leaks at all connection points with system pressurized and pump running
• Verify coolant level is stable in reservoir after pump operation
• Perform battery thermal system self-test through vehicle interface
• Conduct test drive and monitor battery temperature regulation under normal load conditions
• Verify no warning lights or thermal management fault codes are present after test drive
• Perform ADAS recalibration if required by diagnostic scanner
• Final inspection of underbody panels for proper installation and no coolant drips

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