This procedure covers the removal and replacement of the radiator (coolant heat exchanger) used for cooling the electric motor and battery thermal management system on the 2023 Rivian EDV 500.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Replace if damaged
• Lower radiator hose × 1 — Replace if damaged
• Radiator mount grommets × 4 — Replace if worn
• Hose clamps × 4 — Replace with new constant-tension clamps

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Power down the vehicle completely using the center screen shutdown procedure
3. Open the front hood and disconnect the 12V battery negative terminal
4. Wait minimum 5 minutes for high voltage system capacitor discharge
5. Raise and safely support the front of the vehicle on jack stands
6. Remove the front underbody panels to access lower radiator area
7. Remove the front grille assembly using trim removal tools
8. Place coolant drain pan under radiator drain location

Procedure

1. 1

   Drain cooling system
   Locate the radiator drain petcock on the lower driver side of the radiator. Slowly open the drain petcock to release pressure gradually, then fully open to drain coolant into collection pan. Allow system to drain completely (approximately 10 minutes). Once drained, hand-tighten the petcock to prevent coolant loss during radiator removal.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Disconnect upper coolant hose
   Using hose clamp pliers, compress and slide the upper hose clamp away from the radiator neck connection point (approximately 2 inches down the hose). Gently twist the upper radiator hose while pulling to break the seal and remove from the radiator inlet. Have a rag ready to catch residual coolant. Cap the hose end with a plug or plastic bag to prevent contamination.
3. 3

   Disconnect lower coolant hose
   Access the lower radiator hose connection from underneath the vehicle. Compress and slide the lower hose clamp away from the radiator outlet connection. Twist and pull the lower hose from the radiator. Allow any remaining coolant to drain into the collection pan. Cap or plug the hose end.
4. 4

   Disconnect coolant reservoir line
   Locate the small diameter coolant reservoir overflow line connected to the radiator neck or side tank. Release the spring clamp or squeeze clamp and disconnect the overflow line. Position the line away from the work area.
5. 5

   Disconnect cooling fan electrical connector
   Locate the electric cooling fan motor connector mounted on the fan shroud. Press the connector release tab and pull the connector straight out from the fan motor. Secure the wiring harness away from the radiator removal path using wire ties or tape.
6. 6

   Remove radiator mounting bolts
   Locate the radiator mounting bolts at the top corners and lower mounting points (typically 4 total mounting locations). Using the appropriate socket, remove all radiator mount bolts. Note the position of any spacers or mounting brackets. Keep mounting hardware organized for reinstallation.
   ⚠Radiator mounts use plastic reinforced brackets. Do not force or overtighten during reinstallation as this will crack the mounting points.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
7. 7

   Remove radiator assembly
   Carefully lift the radiator assembly upward and toward the engine bay, tilting as necessary to clear the fan shroud and condenser assembly. The radiator and cooling fan shroud typically come out as one assembly on the EDV 500. Guide the assembly up and out, being careful not to damage the condenser fins or radiator core. Tilt to drain any remaining coolant into the drain pan.
8. 8

   Inspect and prepare new radiator
   Inspect the new radiator for shipping damage and ensure all ports are clear of debris. Install new rubber mounting grommets into the radiator mounting bracket locations if not pre-installed. Compare the old and new radiators to verify correct application. Transfer the cooling fan assembly to the new radiator if the fan is not included with the replacement unit.
9. 9

   Install new radiator assembly
   Carefully lower the new radiator assembly into position, aligning the mounting grommets with the frame mounting points. Ensure the radiator sits properly against the condenser mounting tabs without forcing. Verify all hose connection points are accessible and properly oriented.
10. 10

    Install radiator mounting bolts
    Install all radiator mounting bolts with any spacers or brackets in their original positions. Hand-thread all bolts first to ensure proper alignment. Torque the mounting bolts to specification in a cross-pattern (upper driver, lower passenger, upper passenger, lower driver) to ensure even seating.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect coolant hoses
    Connect the lower radiator hose to the radiator outlet, ensuring it is fully seated on the neck. Install a new constant-tension clamp and position it 1/4 inch from the end of the radiator neck. Connect the upper radiator hose to the radiator inlet, fully seating it on the neck. Install a new clamp in the same manner. Torque hose clamps to specification.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reconnect auxiliary connections
    Reconnect the coolant reservoir overflow line to the radiator neck and secure with the spring clamp. Reconnect the cooling fan electrical connector to the fan motor, ensuring it clicks into place. Verify all connections are secure and no hoses are kinked or pinched.
13. 13

    Refill cooling system
    Using the coolant refill funnel installed at the radiator neck or coolant reservoir, slowly add EV Battery/Motor Coolant to the system. Fill until coolant appears at the radiator neck. Allow coolant to settle for 2-3 minutes, then continue adding until the system is full (approximately 10 quarts total capacity). Do not overfill. Install the radiator cap or reservoir cap.
14. 14

    Bleed cooling system
    Locate coolant bleed valves on the cooling system high points (typically on heater hoses or near the electric motor cooling circuits). Open each bleed valve slightly until coolant flows without air bubbles, then close. Reconnect the 12V battery. Start the vehicle and allow it to reach operating temperature with the climate control set to maximum heat. Monitor coolant level and add as necessary. Run through two complete cooling fan cycles.

Reassembly

1. Reinstall the front grille assembly and secure all trim clips
2. Reinstall the front underbody panels and torque fasteners to specification
3. Lower the vehicle from jack stands
4. Verify all coolant connections are dry with no visible leaks
5. Top off coolant reservoir to the FULL COLD mark
6. Reset any cooling system service indicators using diagnostic tool if applicable

Verification

• With engine at operating temperature, verify both cooling fans cycle on and off properly
• Check for coolant leaks at all hose connections, radiator seams, and drain petcock
• Verify coolant level remains stable in the reservoir after cooling system reaches full temperature
• Monitor vehicle thermal management system for proper temperature regulation during a test drive
• Check for diagnostic trouble codes related to cooling system using OBD-II scanner
• Verify cabin heater produces hot air at maximum setting, confirming proper coolant circulation

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