Cooling Fan Assembly

This procedure covers the removal and replacement of the cooling fan assembly on a 2024 Rivian EDV 500 electric delivery van, including electric motor and battery thermal management system components.

Warnings

Tools required

Parts

• Cooling fan assembly × 1 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification
• Fan wiring harness connector seal × 1 — Use OEM specification
• Thermal management system O-rings × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 3 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 2 hours to allow thermal management system to cool
3. Connect Rivian diagnostic tool and document any existing fault codes
4. Using diagnostic tool, command HV battery disconnect and verify zero voltage at contactors
5. Disconnect 12V negative battery terminal and wait 5 minutes for system capacitors to discharge
6. Install HV lockout tag per Rivian safety procedures
7. Raise front of vehicle and secure on jack stands
8. Remove front undertray panels to access cooling system components
9. Place coolant drain pan beneath radiator and fan assembly area

Procedure

1. 1

   Drain thermal management coolant
   Locate the thermal management system drain valve on the lower radiator tank driver side. Slowly open the drain valve and allow coolant to drain into collection pan. Once flow stops, close drain valve. Remove coolant reservoir cap to allow complete draining if necessary.
2. 2

   Disconnect cooling fan electrical connector
   Locate the cooling fan motor electrical connector on the passenger side of the fan shroud. Press the locking tab and disconnect the connector. Secure the wiring harness away from the work area using a zip tie or clip to prevent damage.
3. 3

   Remove upper coolant hose connections
   Using hose clamp pliers, compress and slide the hose clamps away from the fan shroud inlet connection. Carefully twist and pull the upper coolant hose from the fan assembly inlet port. Expect residual coolant spillage. Plug the hose end with a clean rag to prevent contamination.
4. 4

   Remove lower coolant hose connections
   Access the lower coolant outlet connection from beneath the vehicle. Compress hose clamps and slide away from connection points. Remove the lower coolant return hose from the fan assembly outlet port. Verify both O-rings remain with the hoses and inspect for damage.
5. 5

   Remove fan assembly upper mounting bolts
   Locate the two upper mounting bolts securing the fan assembly to the radiator support bracket. These are typically 10mm bolts. Remove both bolts and retain hardware. Support the fan assembly with one hand to prevent it from dropping.
6. 6

   Remove fan assembly lower mounting hardware
   From beneath the vehicle, locate the two lower mounting bolts securing the fan assembly to the front subframe bracket. Remove both lower mounting bolts while supporting the fan assembly. The assembly may have alignment pins that require slight maneuvering to disengage.
7. 7

   Extract cooling fan assembly
   Carefully lower the cooling fan assembly from the vehicle through the bottom. Angle the assembly as needed to clear the radiator fins and AC condenser. Take care not to damage surrounding components. Inspect mounting locations for debris or damage before proceeding.
8. 8

   Prepare new cooling fan assembly
   Unpack new cooling fan assembly and verify it matches the original unit. Install new O-rings onto the coolant inlet and outlet ports, lubricating them with fresh EV coolant. Verify the electrical connector seal is properly seated. Transfer any brackets or hardware from old unit if not included with replacement.
9. 9

   Install new cooling fan assembly
   Guide the new cooling fan assembly into position from beneath the vehicle. Align the mounting pin locations with the radiator support and subframe brackets. Ensure coolant ports are properly oriented and no wiring is pinched. Raise assembly into final position.
10. 10

    Install mounting hardware
    Install lower mounting bolts finger-tight first to hold assembly in position. Install upper mounting bolts finger-tight. Once all four bolts are started, tighten in a cross pattern to ensure even seating. Since no torque specifications are provided, tighten bolts firmly but do not over-torque (estimate 15-20 ft-lbs based on bolt size and application).
11. 11

    Reconnect coolant hoses
    Connect lower coolant return hose to fan assembly outlet port, ensuring O-ring seats properly. Install new hose clamps and position 1/4-inch behind the bead on the port. Connect upper coolant inlet hose to fan assembly inlet port and secure with new hose clamps. Verify all connections are fully seated.
12. 12

    Reconnect electrical connector
    Remove any temporary securing of the fan wiring harness. Connect the electrical connector to the cooling fan motor, ensuring the locking tab clicks into place. Gently tug on connector to verify secure connection. Inspect connector seal for proper seating.
13. 13

    Refill thermal management system
    Using the appropriate EV Battery/Motor Coolant, refill the system through the coolant reservoir. Fill to the cold fill line initially. Close reservoir cap. Using Rivian diagnostic tool, command the cooling system bleed procedure which will cycle pumps and open valves to purge air. Add coolant as level drops during bleeding process.
14. 14

    Restore vehicle power and test system
    Reinstall front undertray panels. Remove HV lockout tag. Reconnect 12V negative battery terminal. Using diagnostic tool, restore HV battery connection following proper Rivian procedures. Command cooling fan operation through diagnostic tool and verify fan runs at multiple speeds. Check for coolant leaks at all connections while system is operating.

Reassembly

1. Verify all coolant connections are tight and show no signs of leakage during pressure testing
2. Ensure coolant level is at proper cold fill line after bleeding procedure is complete
3. Confirm all undertray panels are properly secured and aligned
4. Verify no tools or parts were left in engine compartment
5. Clear any diagnostic codes related to cooling system service mode using Rivian diagnostic tool

Verification

• Start vehicle and allow thermal management system to reach normal operating temperature while monitoring with diagnostic tool
• Verify cooling fan activates automatically at appropriate temperature thresholds
• Check for coolant leaks at fan assembly connections with system at full operating temperature and pressure
• Confirm no abnormal noises from cooling fan during operation at all speed ranges
• Verify coolant level remains stable after complete heat cycle
• Test drive vehicle and monitor thermal management system temperatures remain within normal parameters
• Confirm no diagnostic trouble codes present related to cooling system operation

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