ev-cooling

EV Chiller Unit

for 2023 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Difficulty

Advanced

Time

3.0 h

Tools

Steps

🤖AI-generated, not yet human-verified. This walkthrough was produced by AI and may contain errors. Treat it as a guide, cross-check every step and torque value against the manufacturer's service manual, and stop if anything looks unsafe. This is a moderate-risk job — take extra care.

This procedure covers the removal and replacement of the EV chiller unit on the 2023 Rivian EDV 500, which is responsible for cooling the battery pack and electric drive motors.

Warnings

⚠️High voltage system must be completely de-energized and lockout/tagout procedures followed. Contact with high voltage components can result in severe injury or death.

⚠️Refrigerant must be properly recovered by certified technician using approved equipment. Improper handling can cause frostbite or environmental damage.

⚠EV coolant may be hot even after vehicle has been off. Allow adequate cooling time before opening coolant system.

⚠The chiller unit weighs approximately 35 lbs. Use proper lifting technique or assistance to avoid injury.

ℹ️This procedure requires refrigerant system evacuation and recharge. EPA 609 certification is required for refrigerant handling.

Tools required

Refrigerant recovery machine (R-134a or R-1234yf compatible)Essential

Metric socket set (8mm-19mm)Essential

Torque wrench (10-150 ft-lbs)Essential

Coolant drain pan (minimum 12 quart capacity)Essential

High voltage gloves and safety equipment (Class 0, 1000V minimum)Essential

Trim panel removal tools

Coolant line disconnect tool setEssential

Rivian diagnostic tool or compatible scan toolEssential

Wire tie or hose plug set

Digital multimeterEssential

Parts

EV chiller unit assembly × 1 — Use OEM specification
Chiller mounting gasket/seal × 1 — Use OEM specification
Coolant line O-rings × 4 — Use OEM specification
Refrigerant line seal washers × 2 — Use OEM specification
Electrical connector seals × 2 — Use OEM specification

Fluids

EV Battery/Motor Coolant — 10 qt

Preparation

Park vehicle on level surface and apply parking brake
Verify vehicle has been off for minimum 30 minutes to allow coolant system to cool
Connect Rivian diagnostic tool and document any existing fault codes
Disable high voltage system using diagnostic tool following manufacturer lockout/tagout procedure
Verify high voltage system is de-energized using digital multimeter at service disconnect
Remove 12V auxiliary battery negative terminal and wait 5 minutes for capacitor discharge
Remove driver side front wheel well liner using trim removal tools
Place coolant drain pan under vehicle beneath chiller unit location

Procedure

1
Recover refrigerant from system
Connect refrigerant recovery machine to service ports on chiller unit. Follow machine manufacturer instructions to completely recover all refrigerant from the system. Verify recovery is complete by checking system pressure reaches and maintains vacuum. Document refrigerant quantity recovered for recharge specification.
2
Disconnect refrigerant lines
Using appropriate wrench, disconnect the high-pressure and low-pressure refrigerant lines from the chiller unit. Remove and discard sealing washers. Cap or plug all open refrigerant connections immediately to prevent moisture ingress and contamination.
3
Drain coolant from chiller circuit
Locate coolant drain valve on chiller unit or disconnect lowest coolant line connection. Allow coolant to drain completely into drain pan. If reusing coolant, filter and inspect for contamination. Replace if coolant shows signs of degradation or contamination.
4
Disconnect coolant inlet and outlet lines
Using coolant line disconnect tool, release quick-connect fittings on both coolant inlet and outlet lines to chiller unit. Remove and inspect O-rings on line connections. Plug open coolant lines to prevent spillage and contamination.
5
Disconnect electrical connectors
Locate the two electrical connectors on chiller unit (chiller pump control and temperature sensor). Press connector release tabs and carefully disconnect both connectors. Inspect connector pins for damage or corrosion. Secure connectors away from work area.
6
Remove chiller mounting bolts
Locate and remove all mounting bolts securing chiller unit to vehicle frame (typically 4-6 bolts). Support chiller unit weight while removing final bolts. Note bolt locations and any spacers or washers for reassembly.
7
Remove chiller unit from vehicle
Carefully maneuver chiller unit out of mounting location, taking care not to damage surrounding components or remaining coolant/refrigerant lines. Lower unit through wheel well opening. Place on clean work surface for inspection.
8
Inspect mounting location and prepare for installation
Clean mounting surface on vehicle frame, removing any old gasket material, corrosion, or debris. Inspect mounting points for damage. Check all connection points are clean and free of contamination.
9
Install new chiller unit
Install new mounting gasket/seal on chiller unit if equipped. Carefully position new chiller unit into mounting location through wheel well opening. Align mounting holes with frame mounting points. Start all mounting bolts by hand before tightening.
10
Secure chiller mounting bolts
Tighten chiller mounting bolts in a cross-pattern sequence to ensure even seating. Since no torque specifications are provided in database, follow manufacturer service information for proper torque values. Verify unit is securely mounted without excessive movement.
11
Reconnect coolant lines
Install new O-rings on coolant line connections, lubricating with small amount of coolant. Connect coolant inlet and outlet lines to chiller unit, ensuring quick-connect fittings fully engage and lock. Verify connections by pulling gently on lines.
12
Reconnect refrigerant lines
Install new sealing washers on both high-pressure and low-pressure refrigerant line connections. Connect refrigerant lines to chiller unit and tighten to manufacturer specification using appropriate wrench. Do not overtighten as this may damage sealing surfaces.
13
Reconnect electrical connectors
Inspect and install new electrical connector seals if required. Connect chiller pump control connector and temperature sensor connector, ensuring positive engagement with audible click. Verify connector locks are fully seated.
14
Refill coolant system
Add EV Battery/Motor Coolant through designated fill point until system reaches proper level (approximately 10 quarts total system capacity). Use manufacturer-specified coolant only. Follow bleeding procedure using diagnostic tool to purge air from coolant circuit.
15
Evacuate and recharge refrigerant system
Connect vacuum pump to refrigerant service ports and evacuate system to minimum 29 inches Hg vacuum for at least 30 minutes. Monitor for vacuum decay to verify system integrity. Recharge system with appropriate refrigerant type and quantity per manufacturer specification using recovery/recharge machine.

Reassembly

Reinstall wheel well liner using appropriate fasteners
Reconnect 12V auxiliary battery negative terminal
Using diagnostic tool, re-enable high voltage system following manufacturer procedure
Clear lockout/tagout devices and verify all tools and materials are removed from vehicle

Verification

Use diagnostic tool to activate chiller pump and verify operation without unusual noise
Monitor coolant temperature sensors through diagnostic tool to confirm proper circulation
Check all coolant connections for leaks with system pressurized
Verify refrigerant system pressures match manufacturer specifications for ambient temperature
Check for refrigerant leaks at all connections using electronic leak detector
Monitor system operation through complete thermal cycle to verify proper chiller function
Verify no fault codes present in vehicle systems related to thermal management
Confirm coolant level remains stable after test cycle
Document refrigerant charge quantity and system pressures for service records