Cooling Fan Assembly

This procedure covers the removal and replacement of the cooling fan assembly on a 2023 Rivian EDV 500 Dual Motor AWD electric delivery van, including disconnection of the high-voltage system and coolant system components.

Warnings

Tools required

Parts

• Cooling fan assembly × 1 — Use OEM specification
• Fan mounting grommets × 4 — Use OEM specification
• Coolant hose clamps × 2 — Use OEM specification
• High-voltage connector seal × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Ensure the high-voltage system has been shut down for at least 15 minutes
3. Open the front hood and secure in the fully open position
4. Place wheel chocks behind rear wheels
5. Verify coolant system has cooled to ambient temperature by checking radiator temperature with infrared thermometer or hand test

Procedure

1. 1

   Disconnect 12V battery
   Locate the 12V auxiliary battery in the front compartment driver side. Using a 10mm socket, disconnect the negative battery terminal first, then the positive terminal. Secure terminals away from battery posts using zip ties or tape to prevent accidental reconnection.
2. 2

   Verify high-voltage system de-energization
   Connect the Rivian diagnostic scan tool to the OBD-II port. Navigate to the high-voltage safety menu and initiate the service disconnect procedure. Wait for confirmation that all high-voltage contactors are open. Using a high-voltage rated multimeter, verify 0V DC across the high-voltage bus at the service disconnect point behind the front fascia access panel. Don appropriate high-voltage insulated gloves for all subsequent steps involving orange-jacketed cables.
3. 3

   Drain coolant from cooling fan circuit
   Place a coolant drain pan beneath the front of the vehicle, centered under the cooling fan assembly location. Locate the coolant drain valve on the lower radiator tank (passenger side). Slowly open the drain valve and allow approximately 2 quarts of EV Battery/Motor Coolant to drain into the pan. Close the drain valve once flow stops.
4. 4

   Remove front lower access panel
   Remove eight T30 Torx screws securing the front lower access panel below the cooling fan assembly. Disconnect the ambient air temperature sensor connector located on the back of the panel. Remove the panel and set aside. This provides access to the lower fan mounting points and coolant connections.
5. 5

   Disconnect coolant hoses from fan assembly
   Locate the two coolant hoses connected to the integrated fan shroud assembly. Using pliers, compress and slide the spring-type hose clamps back approximately 2 inches on each hose. Twist and pull the hoses to disconnect from the fan assembly inlet and outlet ports. Have shop towels ready to catch residual coolant. Cap the open hose ends with plugs or tape to prevent contamination.
6. 6

   Disconnect electrical connectors
   Locate the main fan motor connector on the driver side of the fan shroud. Press the connector lock tab and pull straight out to disconnect. If equipped with a secondary sensor connector for fan speed monitoring, disconnect this as well by pressing the red secondary lock tab and then the primary lock. Release all wire harness clips securing the harness to the fan shroud.
7. 7

   Remove upper fan assembly mounting fasteners
   From the top of the engine compartment, locate four mounting bolts securing the top of the fan shroud assembly to the radiator support structure. Remove these using a 10mm socket. Support the fan assembly weight from below as you remove the final fasteners to prevent it from dropping.
8. 8

   Remove lower fan assembly mounting fasteners
   Working from beneath the vehicle through the access panel opening, remove four lower mounting bolts securing the fan assembly to the lower cradle using a 10mm socket. These bolts thread into captured nuts in the chassis structure. Note the position of any alignment dowels or locating pins.
9. 9

   Remove cooling fan assembly
   With all fasteners and connections removed, carefully lift the cooling fan assembly upward and out of the vehicle. The assembly may require angling to clear surrounding components. Take care not to damage radiator fins or nearby wiring harnesses during removal. Place the assembly on a clean work surface.
10. 10

    Inspect mounting points and surrounding components
    Inspect the radiator support mounting points for damage, cracks, or elongated bolt holes. Check rubber mounting grommets for deterioration and replace if hardened or torn. Inspect the radiator core for damage, debris, or fin damage. Clean the mounting surfaces of any dirt, old sealant, or corrosion using a soft brush and shop towels.
11. 11

    Install new cooling fan assembly
    If installing new mounting grommets, press them fully into the mounting holes on the fan shroud until seated. Position the new cooling fan assembly into the mounting location, aligning the lower mounting points first. Ensure any locating dowels engage properly. Support the assembly weight while threading in the lower mounting bolts hand-tight.
12. 12

    Secure fan assembly mounting fasteners
    Install and hand-tighten all four upper mounting bolts. Once all eight mounting bolts (four upper, four lower) are started, tighten them in a cross-pattern sequence to ensure even loading. Since no torque specification is provided in the database, tighten securely using a 10mm socket with moderate force, ensuring the fan assembly sits flush against all mounting points without distortion.
13. 13

    Reconnect electrical connectors
    Route the fan motor wiring harness along its original path, securing it with all original clips to prevent contact with moving parts or hot surfaces. Connect the main fan motor connector, ensuring it clicks into place with the lock tab fully engaged. If equipped, reconnect the secondary sensor connector and verify both primary and secondary locks are engaged. Verify no tension or strain exists on the harness.
14. 14

    Reconnect coolant hoses
    Remove protective caps or tape from the coolant hoses and fan assembly ports. Clean the hose ends and ports with a shop towel. Push each coolant hose firmly onto its respective fan assembly port until fully seated against the stop. Slide the spring-type hose clamps into position over the connection points, ensuring they are positioned in the groove on each port for proper sealing.
15. 15

    Reinstall front lower access panel
    Reconnect the ambient air temperature sensor connector to the back of the access panel. Position the panel into place and install all eight T30 Torx screws, tightening in a cross-pattern to ensure even panel alignment. Verify the panel sits flush with no gaps.

Reassembly

1. Reconnect the 12V battery terminals (positive first, then negative) and torque to manufacturer specification
2. Fill the cooling system with fresh EV Battery/Motor Coolant through the reservoir until reaching the cold fill line
3. Use the Rivian diagnostic scan tool to activate the coolant system bleed procedure to purge air from the system
4. Re-energize the high-voltage system using the scan tool and verify all system checks pass
5. Monitor coolant level during and after the bleeding procedure, adding coolant as needed to maintain proper level

Verification

• With the vehicle in Ready mode, allow the cooling system to reach operating temperature and verify the cooling fan activates when commanded by the thermal management system
• Check all coolant hose connections for leaks while the system is at operating temperature and pressure
• Verify no coolant drips are present on the ground after a 10-minute observation period
• Use the scan tool to verify proper fan operation at multiple speed settings (low, medium, high) and confirm current draw is within specification
• Check for any diagnostic trouble codes related to cooling fan operation and clear if no faults are present
• Verify coolant level is at the hot fill line after system reaches full operating temperature
• Test drive the vehicle and monitor coolant temperature to ensure it remains within normal operating range

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