Radiator Removal and Service

This procedure covers the removal and service of the electric motor and battery cooling radiator on the 2023 Rivian EDV 500, including coolant system draining, hose disconnection, and radiator replacement.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Radiator mounting grommets × 4 — Use OEM specification
• Coolant hose clamps × 6 — Use OEM specification
• Lower splash shield clips × 8 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Verify the vehicle has been parked and powered off for at least 2 hours to allow coolant system to cool and depressurize
2. Ensure the vehicle is parked on a level surface in a well-ventilated area
3. Remove the 12V battery negative terminal to prevent accessory power drain
4. Lift the vehicle and secure on jack stands at all four corners, providing access to the undercarriage
5. Remove all four wheels to access the front lower splash shields and inner fender liners
6. Document any coolant leaks or damage visible before beginning work
7. Place warning tags on the steering wheel indicating high voltage disconnect status

Procedure

1. 1

   Perform high voltage system disconnect
   Access the high voltage battery disconnect located behind the center console lower panel. Use the high voltage disconnect tool to rotate the service disconnect 90 degrees counterclockwise until it stops. Remove the service disconnect handle and store it in a secure location. Wait 5 minutes for the high voltage capacitors to discharge. Use a digital multimeter set to DC voltage to verify 0 volts across the high voltage bus bars before proceeding.
   ⚠️Failure to properly disconnect and verify zero voltage can result in electrocution and death. Do not skip the 5-minute capacitor discharge waiting period.
2. 2

   Remove front lower splash shields and undertray
   Remove the front lower splash shield by removing all perimeter clips and fasteners. Remove the center undertray panels to expose the radiator from below. Disconnect any electrical connectors for undertray-mounted sensors or lights. Set aside all hardware in organized containers for reinstallation.
3. 3

   Drain the EV coolant system
   Locate the coolant drain valve on the lower driver side of the radiator. Position a large drain pan capable of holding at least 12 quarts beneath the radiator. Slowly open the drain valve and allow coolant to drain completely. If equipped, open the coolant reservoir pressure cap slowly to vent the system and improve drainage. Collect all drained coolant in a sealed container for proper disposal or reuse if uncontaminated.
   ⚠EV coolant is toxic and must be disposed of according to local environmental regulations. Do not pour down drains or onto the ground.
4. 4

   Disconnect coolant hoses from radiator
   Using hose clamp pliers, reposition the spring clamps on the upper radiator inlet hose, lower radiator outlet hose, and the two auxiliary coolant lines running to the drive units. Mark each hose connection with tape or marker to ensure correct reconnection. Carefully twist and pull each hose off the radiator fittings. Be prepared for residual coolant spillage. Inspect hoses for cracks, hardening, or deterioration and replace if necessary.
5. 5

   Disconnect electric cooling fan assembly
   Locate the cooling fan electrical connector on the fan shroud. Press the connector locking tab and disconnect the harness. Remove the fan shroud mounting fasteners securing the fan assembly to the radiator. The EDV 500 uses integrated fan modules that typically remain attached to the radiator during removal. If separating the fan, support it carefully to avoid damaging the blades or motor.
6. 6

   Disconnect transmission cooler lines if equipped
   The dual motor EDV transmission cooling system may route through the main radiator. Locate the transmission cooler quick-disconnect fittings on the radiator side tank. Use a small flathead screwdriver to depress the locking tabs while pulling the lines straight out. Cap all open fittings immediately to prevent contamination. Be prepared for additional fluid spillage from these lines.
   ⚠EV transmission fluid and coolant must not be mixed. Keep drain pans separate and label all fluids clearly.
7. 7

   Remove upper radiator mounting brackets
   From the engine compartment, locate the upper radiator mounting brackets on each side of the radiator. Remove the bolts securing these brackets to the radiator support frame. On the EDV 500, these brackets may also secure wiring harness clips and AC line supports, so carefully note their positions for reassembly.
8. 8

   Remove radiator assembly from vehicle
   With all connections and mounting hardware removed, carefully lift the radiator assembly upward and out of the vehicle. The radiator may need to be tilted slightly to clear the AC condenser in front and other components. Have an assistant support the fan shroud side to prevent damage. Inspect the radiator mounting grommets in the lower support cradle and replace if worn or damaged. Place the radiator on a clean work surface for inspection or service.
9. 9

   Inspect and service radiator
   With the radiator removed, perform a thorough inspection of the core for damage, bent fins, or debris blockage. Check all mounting tabs and brackets for cracks. If pressure testing, seal all ports and apply 15 PSI maximum pressure for 2 minutes, checking for leaks. Clean the radiator fins using low-pressure compressed air or water from the engine side outward. If installing a new radiator, transfer any brackets, sensors, or fittings from the old unit to the new one as needed.
10. 10

    Install radiator assembly
    Install new lower mounting grommets into the radiator support cradle if removed or worn. Carefully lower the radiator assembly into position, ensuring the lower mounting pins seat fully into the grommets. Align the upper mounting bracket holes. Install and hand-tighten all upper mounting bracket fasteners before torquing to final specification. Ensure the radiator sits level and does not contact the AC condenser or other components.
11. 11

    Reconnect all coolant hoses and lines
    Reconnect all coolant hoses to their marked positions on the radiator. Ensure each hose is fully seated onto its fitting before repositioning the spring clamps or installing new clamps. Reconnect the transmission cooler lines if equipped, ensuring the quick-disconnect fittings click securely into place. Verify no hoses are kinked, pinched, or routed incorrectly.
12. 12

    Reconnect cooling fan and electrical connections
    Reconnect the cooling fan electrical connector to the fan motor, ensuring the locking tab clicks into place. Verify the connector is fully seated and weather seal is intact. Double-check that no wiring is pinched between components or routed near moving parts.
13. 13

    Refill coolant system and bleed air
    Close the radiator drain valve. Slowly refill the cooling system with the specified EV Battery/Motor Coolant through the coolant reservoir. Fill until coolant reaches the MAX line. With the reservoir cap off, activate the coolant pump through the vehicle service menu or by briefly powering on the vehicle systems. Add additional coolant as the system bleeds air and the level drops. Continue until no more air bubbles emerge and the level stabilizes. Install the reservoir cap.
14. 14

    Reinstall undertray and splash shields
    Reinstall all lower splash shields and undertray panels, ensuring all clips and fasteners are properly seated. Reconnect any electrical connectors that were disconnected. Reinstall all four wheels and torque lug nuts to specification in a star pattern.
15. 15

    Restore high voltage system and power
    Reinstall the high voltage service disconnect handle by inserting it and rotating 90 degrees clockwise until it locks into place. Verify the disconnect is fully seated. Reconnect the 12V battery negative terminal. Remove all warning tags from the vehicle.

Reassembly

1. Verify all coolant hose clamps are tight and positioned correctly before starting the vehicle
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Double-check that no tools or hardware were left in the engine compartment or undercarriage
4. Verify the high voltage service disconnect is fully engaged and locked before operating the vehicle
5. Check coolant level after the first 50 miles of driving and top off if necessary

Verification

• Power on the vehicle and allow the cooling system to reach operating temperature while monitoring for leaks around all hose connections and the radiator
• Use the vehicle's diagnostic system to check for any coolant system fault codes or temperature warnings
• Verify the electric cooling fans activate properly when the system reaches operating temperature
• Check coolant level in the reservoir after the system reaches full operating temperature and top off to the MAX line if needed
• Perform a test drive of at least 15 minutes including highway speeds, then recheck for leaks and verify coolant level remains stable
• Monitor battery and drive unit temperatures through the vehicle interface for the first several drive cycles to ensure proper cooling system operation

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