Coolant Outlet

This procedure covers the removal and replacement of the coolant outlet on the 2023 Rivian EDV 500 dual motor electric drivetrain, including coolant system draining, component removal, and refilling procedures.

Warnings

Tools required

Parts

• Coolant outlet assembly × 1 — Use OEM specification
• Coolant outlet gasket or O-ring seal × 1 — Use OEM specification
• Hose clamps (if reusing old clamps is not recommended) × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and ensure it is fully powered off
2. Allow cooling system to cool for minimum 2 hours if vehicle was recently operated
3. Disconnect 12V battery negative terminal and wait 5 minutes for system discharge
4. Verify high voltage system is deactivated using Rivian diagnostic tool
5. Remove engine cover or access panels as needed to access coolant outlet location on motor assembly
6. Place coolant drain pan beneath vehicle under drain point
7. Document coolant outlet orientation and hose routing with photos for reassembly reference

Procedure

1. 1

   Drain cooling system
   Locate the coolant drain valve on the bottom of the cooling system reservoir or at the lowest point of the system. Slowly open the drain valve and allow coolant to drain into the collection pan. If no drain valve is accessible, carefully loosen the lower radiator hose at the lowest connection point to drain the system. Collect all coolant for proper disposal.
   ⚠Coolant may still be warm. Open drain valve slowly to prevent splashing.
2. 2

   Disconnect electrical connectors
   Locate any electrical connectors attached to the coolant outlet assembly, such as coolant temperature sensors or position sensors. Press the release tabs and carefully disconnect all electrical connectors. Use a multimeter to verify no voltage is present on connector pins before handling.
3. 3

   Remove coolant hoses from outlet
   Using hose clamp pliers, compress or loosen the hose clamps securing the coolant hoses to the outlet assembly. Slide clamps away from the connection points. Gently twist and pull the coolant hoses off the outlet nipples. Be prepared for residual coolant spillage. Mark hose positions if multiple hoses connect to outlet.
   ⚠Residual coolant will drain from hoses. Keep drain pan positioned to catch spillage.
4. 4

   Remove coolant outlet mounting fasteners
   Locate and remove all mounting bolts or fasteners securing the coolant outlet to the motor housing or coolant system component. Note the location and length of each fastener as they may vary. Carefully support the outlet assembly as the final fastener is removed to prevent dropping.
5. 5

   Remove coolant outlet assembly
   Carefully pull the coolant outlet assembly away from the mounting surface. If resistance is felt, check for any remaining fasteners or stuck sealing surfaces. Use a plastic pick to gently separate gasket material if outlet is stuck, being careful not to damage mating surfaces.
6. 6

   Clean mating surfaces
   Thoroughly clean all coolant outlet mating surfaces on both the motor housing and outlet mounting location. Remove all old gasket material, corrosion, or debris using a plastic scraper. Wipe surfaces clean with shop towels. Inspect mounting surface for damage, cracks, or warping that could cause leaks.
   ⚠Do not use metal scrapers on aluminum surfaces as this can cause damage and leak paths.
7. 7

   Install new gasket or O-ring
   Install the new coolant outlet gasket or O-ring seal onto the new coolant outlet assembly. Ensure the gasket is properly seated in its groove and correctly oriented. Apply a light coating of fresh coolant to the O-ring if applicable to aid installation and sealing.
8. 8

   Install new coolant outlet
   Carefully position the new coolant outlet assembly onto the mounting surface, ensuring proper alignment with the coolant passages and bolt holes. Press firmly to seat the gasket. Install all mounting fasteners hand-tight first, then tighten in a cross-pattern sequence to ensure even gasket compression. Since no torque specifications are provided in the database, tighten fasteners to manufacturer specification found in service manual or use appropriate torque for fastener size and material.
9. 9

   Reconnect coolant hoses
   Slide coolant hoses onto the outlet nipples, ensuring they are fully seated to the base of each nipple. Position new or reused hose clamps over the hose connection points and tighten securely. Verify each connection is secure and hoses are routed correctly per documentation photos.
10. 10

    Reconnect electrical connectors
    Reconnect all electrical connectors to the coolant outlet assembly, ensuring each connector clicks into place and is fully seated. Verify connector locks are engaged.
11. 11

    Refill cooling system
    Close the coolant drain valve if it was used. Using the coolant refill funnel, slowly add the specified EV battery/motor coolant through the cooling system reservoir. Fill to the cold fill line. Add coolant slowly to minimize air bubble introduction. Allow time for coolant to settle and add more as needed.
    ⚠Only use Rivian-specified EV coolant. Do not mix with standard automotive coolant.
12. 12

    Bleed cooling system
    Connect the Rivian diagnostic tool to the vehicle's OBD-II port. Navigate to the cooling system service functions and initiate the coolant bleeding procedure. The system will cycle coolant pumps and open control valves to purge air from the system. Follow all on-screen prompts. Monitor coolant level during bleeding and add coolant as needed to maintain proper level.
    ℹ️Proper bleeding is critical for EV cooling system function. Air pockets can cause overheating of motors or battery components.
13. 13

    Reconnect 12V battery
    Reconnect the 12V battery negative terminal. Power on the vehicle and verify all cooling system warning lights extinguish after system initialization.

Reassembly

1. Reinstall all engine covers and access panels removed during preparation
2. Verify coolant level is at the proper cold fill line on the reservoir
3. Inspect all connections for signs of coolant leakage
4. Dispose of old coolant according to local environmental regulations

Verification

• Start vehicle and allow cooling system to reach operating temperature while monitoring for leaks around the new coolant outlet
• Use Rivian diagnostic tool to verify coolant temperature sensors are reading properly and no cooling system fault codes are present
• Check coolant level after vehicle reaches operating temperature and top off if needed to the hot fill line
• Verify coolant outlet area is dry with no signs of seepage or dripping after test drive
• Perform a 15-minute test drive and recheck coolant level and outlet connections for any leaks

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