This procedure covers the removal and replacement of the EV radiator (cooling system heat exchanger) on a 2023 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• EV radiator assembly × 1 — Use OEM specification
• Radiator mounting grommets × 4 — Use OEM specification
• Lower coolant hose O-rings × 2 — Use OEM specification
• Upper coolant hose O-rings × 2 — Use OEM specification
• Radiator fan connector seal × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure high voltage system has been powered down for at least 5 minutes
3. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Using Rivian diagnostic software, verify high voltage system is disabled and place vehicle in service mode
5. Raise front of vehicle and secure on jack stands at designated lift points
6. Remove front belly pan and lower aerodynamic panels
7. Place drain pan beneath radiator drain location
8. Allow cooling system to reach ambient temperature (verify coolant temperature below 100°F)

Procedure

1. 1

   Drain cooling system
   Locate the coolant drain valve on the lower driver side of the radiator. Attach drain hose to valve and route to drain pan. Open drain valve and allow system to drain completely. Once drained, close drain valve. If equipped, open coolant reservoir cap to aid draining (only after pressure is released).
   ⚠Dispose of used EV coolant according to local environmental regulations. Do not mix with conventional coolant.
2. 2

   Disconnect coolant hoses
   Locate the upper and lower coolant hoses connecting to the radiator. Using hose clamp pliers, release the spring clamps on each hose. Carefully twist hoses to break seal, then pull straight off radiator connections. Inspect O-rings and replace if damaged. Cap open hose ends to prevent contamination.
3. 3

   Remove front fascia and grille assembly
   Remove Torx fasteners securing upper grille assembly (typically 6-8 T30 screws). Release plastic clips along top edge using trim tools. Disconnect ambient temperature sensor connector if equipped in grille. Carefully pull grille forward and remove from vehicle. Set aside in protected area.
4. 4

   Disconnect radiator fan electrical connections
   Locate the cooling fan motor connector on the back of the radiator shroud assembly. Press release tab and disconnect connector. If equipped with dual fans, disconnect both fan connectors. Inspect connector seals and replace if deteriorated.
5. 5

   Disconnect transmission cooler lines
   Locate the transmission cooler hard lines connecting to the integrated cooler on the radiator tank. Using appropriate wrench, disconnect cooler line fittings. Be prepared for residual fluid spillage. Cap open lines immediately to prevent contamination and fluid loss.
   ℹ️EDV transmission cooler lines are integrated into the radiator end tank on this model.
6. 6

   Remove AC condenser mounting brackets
   The AC condenser is mounted in front of the radiator. Remove the mounting brackets securing condenser to radiator (typically 4 bolts). Carefully separate condenser and support it without disconnecting refrigerant lines. Use wire or straps to secure condenser to frame, keeping refrigerant lines free from stress.
   ⚠Do not disconnect AC lines unless system has been properly evacuated. Support condenser weight to prevent line damage.
7. 7

   Remove radiator upper mounting brackets
   Locate the upper radiator mounting brackets (typically one on each side). Remove bolts securing brackets to radiator support. Note exact positioning of brackets and any shims for proper reinstallation. Set brackets and hardware aside in organized manner.
8. 8

   Remove radiator lower mounting fasteners
   From underneath vehicle, locate the lower radiator mounting points. Remove bolts or clips securing radiator to lower support cradle. Note that radiator typically sits on rubber isolation grommets at lower mounts. Inspect grommets for deterioration and replace if necessary.
9. 9

   Remove radiator assembly
   With all connections and mounts disconnected, carefully lift radiator assembly upward and toward rear of vehicle to clear lower mounting pins. Angle radiator to clear any remaining obstructions. Remove radiator from vehicle with fan shroud attached. Handle carefully to avoid damaging cooling fins or fan blades.
   ⚠Radiator assembly is bulky and weighs approximately 25-30 lbs. Use proper lifting technique or have assistant help.
10. 10

    Transfer components to new radiator
    If cooling fans are attached to old radiator, remove mounting screws and transfer fans to new radiator assembly. Transfer any sensors, brackets, or mounting hardware to new radiator. Ensure all rubber grommets and isolation mounts are installed on new radiator. Verify new radiator part number matches application.
11. 11

    Install new radiator assembly
    Position new radiator assembly into vehicle, aligning lower mounting pins with grommets in radiator support. Angle radiator to clear obstructions and carefully lower into position. Ensure radiator sits properly on lower mounting points before proceeding.
12. 12

    Install mounting brackets and hardware
    Install lower mounting fasteners and secure radiator to lower support. Install upper mounting brackets in exact original positions with any shims noted during removal. Secure all mounting hardware but do not fully tighten until radiator alignment is verified.
13. 13

    Reconnect cooling system connections
    Install new O-rings on radiator hose connections, lightly lubricating with coolant. Reconnect upper and lower coolant hoses, ensuring hoses are fully seated. Install spring clamps in original positions. Reconnect transmission cooler lines and tighten fittings. Reconnect all cooling fan electrical connectors, ensuring positive lock engagement.
14. 14

    Reinstall AC condenser and front fascia
    Remove condenser support and reposition condenser against radiator. Install condenser mounting brackets and secure to radiator. Reinstall front grille assembly, reconnecting ambient temperature sensor if equipped. Secure all Torx fasteners and verify all trim clips are properly engaged.
15. 15

    Fill and bleed cooling system
    Fill cooling system with correct quantity (10 quarts) of Rivian-approved EV Battery/Motor Coolant through coolant reservoir. Use vacuum fill tool if available for optimal results. With reservoir cap off, use Rivian diagnostic software to activate cooling pumps and cycle system to purge air. Monitor coolant level and add as needed. Once system is bled, install reservoir cap and verify proper coolant level at cold fill mark.
    ⚠Incomplete bleeding can cause thermal management system malfunctions and potential battery damage. Follow Rivian bleeding procedure exactly.

Reassembly

1. Reinstall lower belly pan and aerodynamic shields using original fasteners
2. Reconnect 12V battery negative terminal
3. Exit service mode using Rivian diagnostic software
4. Verify all electrical connectors are properly seated and locked
5. Double-check all coolant connections for proper installation and clamp positioning
6. Ensure no tools or parts remain in engine compartment

Verification

• Using Rivian diagnostic software, verify no cooling system fault codes are present
• Start vehicle and bring cooling system to operating temperature while monitoring for leaks
• Verify both cooling fans operate properly through diagnostic commands
• Check coolant level after reaching operating temperature and top off if needed
• Perform pressure test of cooling system to 15 psi and verify no pressure loss over 5 minutes
• Test drive vehicle and monitor coolant temperature remains within normal range (typically 150-190°F)
• Verify battery thermal management system is functioning properly through diagnostic data
• Inspect all connection points for signs of coolant leakage after test drive
• Recheck coolant level after vehicle cools and top off to cold fill mark if necessary

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