Cooling Fan Motor

This procedure covers the removal and replacement of the cooling fan motor in the 2023 Rivian EDV 500 electric delivery van, which is part of the battery and motor thermal management system.

Warnings

Tools required

Parts

• Cooling fan motor assembly × 1 — Use OEM specification
• Fan motor mounting hardware kit × 1 — Use OEM specification
• Coolant hose clamps × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob to a distance of at least 20 feet from the vehicle
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
4. Follow manufacturer procedures to disconnect high-voltage battery system using service disconnect located in front trunk area
5. Wait minimum 10 minutes for high-voltage system capacitor discharge
6. Verify high-voltage system is de-energized using appropriate test equipment
7. Place warning tags on steering wheel and high-voltage disconnect indicating service in progress
8. Allow cooling system to cool to ambient temperature (minimum 2 hours after last operation)

Procedure

1. 1

   Access underbody splash shields
   Raise and support the vehicle on jack stands or a lift. Remove the front underbody splash shields to access the cooling fan assembly. Remove fasteners securing the shields and set aside in organized manner for reinstallation.
2. 2

   Locate cooling fan motor
   Identify the cooling fan motor assembly mounted in the front cooling module. The EDV 500 has the fan motor located behind the front fascia, integrated with the thermal management system. Take a photo of electrical connector routing and hose positions for reference during reassembly.
3. 3

   Drain cooling system
   Position drain pan beneath the cooling fan motor area. Locate the drain valve on the cooling circuit associated with this fan motor. Open drain valve and allow approximately 2 quarts of EV Battery/Motor Coolant to drain into pan. Close drain valve once flow stops.
4. 4

   Disconnect electrical connector
   Locate the electrical connector at the cooling fan motor. Press the locking tab and carefully disconnect the connector from the fan motor. Inspect connector pins for corrosion or damage. Secure the connector away from the work area to prevent damage.
5. 5

   Remove coolant hoses
   Using appropriate pliers, release the coolant hose clamps on both inlet and outlet hoses connected to the fan motor housing. Carefully twist and pull hoses from the fan motor nipples. Be prepared for residual coolant spillage. Plug hose ends with clean rags to prevent contamination.
6. 6

   Remove fan motor mounting fasteners
   Remove the mounting bolts or fasteners securing the cooling fan motor to the mounting bracket. The EDV 500 typically uses four mounting points. Support the fan motor assembly with one hand while removing the final fastener to prevent it from falling.
7. 7

   Extract cooling fan motor
   Carefully maneuver the cooling fan motor assembly out of its mounting location. Be mindful of sharp edges and surrounding components. Inspect the mounting bracket and surrounding area for debris, corrosion, or damage that should be addressed before installing the new motor.
8. 8

   Inspect and clean mounting area
   Clean the mounting surface and bracket with shop towels. Remove any old gasket material, coolant residue, or debris. Inspect coolant hose nipples on the vehicle side for cracks or damage. Replace hoses if any degradation is observed.
9. 9

   Install new cooling fan motor
   Position the new cooling fan motor into the mounting bracket, aligning all mounting holes. Install mounting bolts and hand-tighten in a cross-pattern. Since no torque specifications are provided in the database, tighten fasteners securely using proper judgment for the fastener size, ensuring even pressure around the mounting points.
10. 10

    Reconnect coolant hoses
    Install the coolant inlet and outlet hoses onto the new fan motor nipples. Ensure hoses are fully seated. Install new coolant hose clamps and position them properly on the hose barbs. Tighten clamps securely to prevent coolant leaks.
11. 11

    Reconnect electrical connector
    Connect the electrical connector to the new cooling fan motor, ensuring it clicks into place and the locking tab engages fully. Verify connector is secure by gently pulling on it. Route any wiring harnesses properly using cable ties if necessary to match original routing.
12. 12

    Refill cooling system
    Using the appropriate filling procedure for the Rivian thermal management system, add EV Battery/Motor Coolant to the system. Fill slowly to prevent air pockets. Add approximately 2 quarts or until system reaches proper level. Refer to fill cap markings for proper level.
13. 13

    Bleed cooling system
    Follow Rivian-specific bleeding procedure for the thermal management system. This may involve running the cooling pump in service mode or using bleed screws if equipped. Ensure all air is purged from the system. Top off coolant as needed during bleeding process.
14. 14

    Reinstall underbody shields
    Reinstall all underbody splash shields and fasteners removed during disassembly. Ensure all fasteners are properly seated and tightened. Verify no tools or parts have been left in the work area.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Follow manufacturer procedures to reconnect high-voltage battery system
3. Remove all warning tags from vehicle
4. Ensure all panels and shields are properly secured
5. Double-check all electrical connections are fully engaged
6. Verify coolant level is correct in expansion tank

Verification

• Power on the vehicle and verify no warning lights or fault codes are present on the instrument cluster
• Using Rivian diagnostic software if available, command the cooling fan motor to operate and verify proper operation at multiple speed settings
• Listen for unusual noises from the fan motor during operation
• Inspect all coolant connections for leaks while system is operating
• Allow vehicle to reach normal operating temperature and verify fan motor cycles on and off appropriately
• Check coolant level after test drive and top off if necessary
• Perform final inspection of work area for any coolant leaks or loose connections
• Clear any stored fault codes and verify no new codes are present
• Test drive vehicle and monitor thermal management system performance

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