This procedure involves removing and replacing the battery thermal management module responsible for regulating battery pack temperature in the 2024 Rivian EDV 500.

Warnings

Tools required

Parts

• Battery thermal management module × 1 — Use OEM specification
• Thermal management module gasket/seal × 1 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure battery state of charge is below 30% for safety (check via instrument cluster)
3. Connect Rivian diagnostic tool and document any existing fault codes related to thermal management
4. Place high-voltage safety mat in work area
5. Open front hood and locate 12V battery disconnect
6. Disconnect 12V negative battery terminal and wait 2 minutes for vehicle systems to power down
7. Don high-voltage insulated gloves and safety equipment
8. Lift vehicle on appropriate lift or jack stands to access underbody
9. Remove underbody splash shields to access battery pack and thermal management components

Procedure

1. 1

   De-energize high-voltage system
   Locate the high-voltage service disconnect (orange connector) on the battery pack. Remove the service disconnect cover using appropriate tools. Pull the service disconnect plug straight out and store in a secure location away from the vehicle. Install the lockout tag to prevent accidental reconnection. Wait minimum 15 minutes for high-voltage system capacitors to discharge.
2. 2

   Verify high-voltage isolation
   Using a high-voltage capable digital multimeter, verify voltage between high-voltage positive and negative bus bars reads less than 5V DC. Verify voltage between high-voltage positive and vehicle chassis ground reads less than 5V DC. Verify voltage between high-voltage negative and vehicle chassis ground reads less than 5V DC. Document all readings. Do not proceed if any voltage reading exceeds 5V DC.
3. 3

   Drain battery coolant system
   Locate the battery thermal management coolant drain valve on the driver side of the battery pack. Position drain pan beneath the drain valve. Open the drain valve and allow coolant to drain completely (approximately 10 quarts). If equipped, open coolant reservoir cap to allow system to vent and drain fully. Close drain valve once system is empty.
4. 4

   Disconnect coolant lines from thermal management module
   Locate the inlet and outlet coolant hoses connecting to the thermal management module. Using appropriate tools, loosen and remove the hose clamps from both coolant connections. Carefully disconnect the coolant hoses from the module, being prepared for residual coolant spillage. Cap or plug the open coolant lines to prevent contamination.
5. 5

   Disconnect electrical connectors
   Locate all electrical connectors on the thermal management module including the main control connector, temperature sensor connectors, and pump power connectors. Press release tabs and carefully disconnect each connector. Inspect connector pins for corrosion or damage. Label connectors if necessary to ensure correct reassembly.
6. 6

   Support battery pack
   Position the battery pack lifting fixture or support stands beneath the battery pack to support its weight. The thermal management module is integrated with the battery pack structure and removal may affect pack stability. Ensure supports are positioned at manufacturer-specified lift points to prevent damage.
7. 7

   Remove thermal management module mounting hardware
   Locate all mounting bolts securing the thermal management module to the battery pack assembly (typically 8-12 bolts around the perimeter). Using appropriate metric sockets, remove all mounting bolts in a cross-pattern sequence to prevent binding. Keep all hardware organized for reinstallation. Note the location of any ground straps or brackets that may be secured by mounting bolts.
8. 8

   Remove thermal management module
   Carefully lower the thermal management module from the battery pack assembly. The module may weigh 40-60 lbs, so use proper lifting technique or have an assistant help. Check that all electrical connectors and coolant lines are disconnected before fully removing. Inspect the mounting surface on the battery pack for damage or debris.
9. 9

   Prepare mounting surface and install new module
   Clean the battery pack mounting surface where the thermal management module attaches using a wire brush or contact cleaner. Remove all old gasket material and ensure surface is clean and dry. Install the new thermal management module gasket/seal according to manufacturer orientation. Carefully lift the new thermal management module into position, aligning mounting holes with the battery pack. Hand-thread all mounting bolts to ensure proper alignment before tightening.
10. 10

    Torque mounting hardware
    Tighten all thermal management module mounting bolts in a cross-pattern sequence to ensure even sealing and prevent warping. Since no specific torque values are provided in the database, follow the torque specifications provided with the replacement module or in the Rivian factory service manual. Verify all bolts are properly torqued and recheck after initial tightening.
11. 11

    Reconnect electrical connections
    Reconnect all electrical connectors to the thermal management module in reverse order of removal. Ensure each connector clicks fully into place and locking tabs are engaged. Verify connector seals are properly seated. Replace any damaged high-voltage connector seals. Check that no wires are pinched or under strain.
12. 12

    Reconnect coolant lines
    Remove caps or plugs from coolant lines. Connect the inlet and outlet coolant hoses to the appropriate ports on the new thermal management module. Install new coolant hose clamps and tighten to secure connections. Ensure hoses are fully seated on barbed fittings before tightening clamps. Double-check that inlet and outlet connections are correct per service diagram.
13. 13

    Refill coolant system
    Close the battery thermal management coolant drain valve. Using approved EV Battery/Motor Coolant, slowly refill the system through the coolant reservoir. Fill to the appropriate level mark (approximately 10 quarts total capacity). Allow time for air to escape from the system. If equipped with coolant bleed screws, open them to release trapped air, then close when coolant flows freely without bubbles.
14. 14

    Reconnect high-voltage system and 12V battery
    Remove lockout tag and reinstall the high-voltage service disconnect plug, ensuring it clicks fully into place. Reinstall the service disconnect cover. Reconnect the 12V negative battery terminal. Remove high-voltage safety equipment. Reinstall underbody splash shields and lower vehicle from lift.
15. 15

    Commission system and perform diagnostic checks
    Connect Rivian diagnostic tool and power up vehicle systems. Run thermal management system commissioning procedure per factory diagnostic software. Command the thermal management module to activate and verify pump operation and coolant flow. Check for coolant leaks at all connections. Monitor coolant temperature sensors to verify proper reading. Clear any diagnostic trouble codes that were set during the replacement. Perform a thermal management system self-test and verify all tests pass.

Reassembly

1. Ensure all underbody panels and shields are reinstalled and secured
2. Verify coolant level is correct after system has been operated
3. Recheck all electrical connections for proper seating after initial operation
4. Verify no coolant leaks are present after test cycle

Verification

• Connect diagnostic tool and verify no active or pending fault codes related to battery thermal management
• Start vehicle and allow thermal management system to run through a complete cycle
• Monitor coolant temperature using diagnostic tool to verify proper regulation within normal operating range (typically 15-35°C)
• Verify coolant pump operation by listening for pump activation and checking coolant flow
• Check that battery pack temperatures are being maintained within specification during operation
• Perform a test drive and monitor battery thermal management system performance under load
• Recheck coolant level after test drive and top off if necessary
• Verify no coolant leaks are present around thermal management module connections
• Document all diagnostic readings and save final diagnostic scan for service records

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