This procedure covers the removal and replacement of the EV coolant lines that supply coolant to the battery pack and electric drive motors on the 2023 Rivian EDV 500.

Warnings

Tools required

Parts

• EV coolant line kit (specific to affected lines) × 1 — Use OEM specification
• Coolant line O-rings and seals × 1 — Use OEM specification
• Quick-connect coupling clips × 4 — Use OEM specification
• Underbody shield fasteners × 10 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level ground and apply parking brake. Place wheel chocks at all four wheels.
2. Ensure vehicle has been off for at least 2 hours to allow coolant system to depressurize and cool.
3. Connect Rivian diagnostic scanner and verify no active high voltage faults.
4. Access the 12V battery in the front compartment and disconnect the negative terminal.
5. Wait 5 minutes for vehicle systems to fully power down.
6. Put on high voltage insulated gloves and safety equipment.
7. Access the high voltage service disconnect (located under rear seat area) and remove the service plug. Install lockout/tagout device.
8. Wait an additional 5 minutes for high voltage capacitors to discharge.
9. Using a CAT III rated multimeter, verify 0V DC across high voltage bus bars at the battery pack service disconnect location.
10. Raise vehicle on lift to working height or use jack stands rated for vehicle weight (approximately 9,000 lbs).
11. Remove underbody panels and shields to access coolant lines running along frame rails and to drive units.
12. Place large drain pan under vehicle, positioned to catch coolant from multiple drain points.

Procedure

1. 1

   Drain the EV coolant system
   Locate the coolant reservoir in the front compartment. Remove the reservoir cap slowly to release any residual pressure. Locate the coolant drain valve on the lowest point of the coolant loop (typically near the front motor or on the battery pack underside). Attach a drain hose to the valve and open it to drain coolant into the collection pan. Allow system to drain completely, which may take 10-15 minutes.
2. 2

   Disconnect battery pack coolant lines
   Locate the coolant line connections at the battery pack (typically 2-4 connection points on the pack perimeter). Clean the area around each quick-connect coupling. Using hose clamp pliers or appropriate tool, compress the quick-connect retaining clips and carefully pull the coolant lines straight out from the battery pack fittings. Inspect the O-rings and seals for damage. Cap or plug the open battery pack ports immediately to prevent contamination.
3. 3

   Disconnect front motor coolant lines
   Locate the coolant line connections at the front drive unit. There will typically be an inlet and outlet line. Release the quick-connect couplings using the same method as Step 2. Note the routing and orientation of lines for reinstallation. Allow any remaining coolant to drain from the disconnected lines into your drain pan.
4. 4

   Disconnect rear motor coolant lines
   Move to the rear drive unit and locate its coolant connections. Release the quick-connect couplings and disconnect the coolant lines. The rear drive unit may have additional coolant temperature sensors or pressure sensors connected to the lines - carefully disconnect any electrical connectors before fully removing lines.
5. 5

   Remove coolant line mounting brackets
   Follow the coolant lines along their routing path under the vehicle. Locate all mounting brackets, clips, and fasteners that secure the coolant lines to the frame rails and underbody. Remove these fasteners using appropriate metric sockets. Keep fasteners organized by location for reassembly. Note that some brackets may also secure electrical harnesses or brake lines.
6. 6

   Remove damaged coolant lines
   Carefully work the old coolant lines free from their routing path. Pay attention to how they pass through frame channels, over crossmembers, and around other components. Take photos or make notes of the routing for reference during installation. Inspect adjacent components for any coolant damage or corrosion.
7. 7

   Inspect coolant system components
   With lines removed, inspect all connection ports on the battery pack, front drive unit, and rear drive unit. Check for corrosion, damage, or debris in the quick-connect fittings. Inspect the coolant pump (typically located near front drive unit) for leaks or damage. Check the coolant reservoir for cracks or contamination. Clean all connection points with lint-free cloth.
8. 8

   Prepare new coolant lines
   Unpack the new coolant line kit and verify all components are present. Install new O-rings and seals on the quick-connect fittings of the new lines. Lightly lubricate the O-rings with clean EV coolant or approved assembly lubricant. Do not use petroleum-based lubricants. Verify that new quick-connect clips are installed on each fitting.
9. 9

   Route and install new coolant lines
   Beginning with the longest runs, carefully route the new coolant lines following the exact path of the original lines. Ensure lines do not contact sharp edges, hot surfaces, or moving components. Feed lines through frame channels and support brackets. Maintain proper clearance from exhaust components, suspension components, and the driveshaft if equipped.
10. 10

    Connect coolant lines to battery pack
    Remove the protective caps from the battery pack coolant ports. Align the coolant line quick-connect fittings with the battery pack ports and push firmly until you hear and feel a positive click. Tug gently on each line to verify it is securely locked in place. The line should not pull out with moderate force.
11. 11

    Connect coolant lines to drive motors
    Connect the coolant lines to the front drive unit inlet and outlet ports using the same push-to-connect method. Ensure proper orientation (inlet vs outlet). Repeat for the rear drive unit connections. Reconnect any coolant temperature or pressure sensor electrical connectors that were removed.
12. 12

    Install mounting brackets and secure lines
    Install all coolant line mounting brackets and clips along the routing path. Ensure lines are properly seated in brackets before tightening fasteners. Lines should be secure but not over-compressed by brackets. Verify adequate clearance from all moving and heat-generating components. Double-check that no lines are kinked or twisted.
13. 13

    Fill coolant system
    Close the coolant drain valve. Using the specified EV Battery/Motor Coolant, slowly fill the system through the coolant reservoir. Fill to the cold fill line (approximately 10 quarts total capacity). The filling process may need to be done in stages as coolant works through the system. Gently squeeze accessible coolant hoses to help purge air from the system.
14. 14

    Bleed air from coolant system
    Many EV coolant systems have air bleed valves at high points in the system. Locate and open any bleed valves (typically near the drive units or at the coolant reservoir). With the reservoir cap off, use the diagnostic scanner to activate the coolant pump in service mode. Run the pump for 30-second intervals, allowing coolant to circulate and air to escape. Top off reservoir as needed. Continue until no air bubbles are visible and coolant flows steadily from bleed points. Close all bleed valves.
15. 15

    Reinstall underbody panels and restore power
    Reinstall all underbody shields and panels, ensuring proper fitment and all fasteners are secure. Lower the vehicle from the lift. Reinstall the high voltage service disconnect plug (remove lockout/tagout device). Reconnect the 12V battery negative terminal. Using the diagnostic scanner, clear any stored fault codes related to the high voltage system being disconnected.

Reassembly

1. Ensure all quick-connect coolant fittings are fully seated and locked with positive engagement
2. Verify all mounting brackets are tight and coolant lines have proper support along their entire length
3. Confirm coolant level is at the proper cold fill mark on the reservoir
4. Ensure high voltage service disconnect is fully installed and locked
5. Verify all underbody panels are secure and no tools or parts were left under the vehicle

Verification

• With the vehicle powered on (ready mode), use the diagnostic scanner to monitor coolant temperature sensors at the battery pack, front drive unit, and rear drive unit. Verify all sensors show reasonable ambient temperature readings.
• Activate the coolant pump using the diagnostic scanner and verify pump operation (listen for pump noise from front compartment).
• Check coolant level in reservoir after running pump - top off if necessary.
• Perform a visual inspection of all coolant line connections while the system is running. Look for any signs of leakage, particularly at quick-connect fittings.
• If available, connect a coolant pressure tester to the system and pressurize to 15 PSI. Hold pressure for 5 minutes and verify no pressure drop, indicating no leaks.
• Road test the vehicle for 15-20 minutes, including highway speeds, to bring the system up to operating temperature.
• After road test, recheck coolant level (system should be warm but not hot). Top off to the hot fill line if necessary.
• Use diagnostic scanner to verify no coolant temperature warnings or faults. Check that battery pack, front motor, and rear motor temperatures are within normal operating range (typically 40-60°C).
• Perform a final under-vehicle inspection with a flashlight to verify no coolant drips or wet spots at any connection points.

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