This procedure covers the removal and replacement of the EV chiller unit on the 2024 Rivian EDV 500, which is part of the thermal management system for battery and motor cooling.

Warnings

Tools required

Parts

• EV Chiller Unit × 1 — Use OEM specification
• Chiller mounting bolts/hardware kit × 1 — Use OEM specification
• Refrigerant line O-rings × 4 — Use OEM specification
• Coolant line sealing washers × 4 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off for minimum 2 hours to allow cooling system to depressurize and cool
3. Access the HV disconnect following manufacturer procedures and place lockout tag
4. Disconnect 12V auxiliary battery negative terminal
5. Raise vehicle and secure on jack stands at manufacturer-specified lift points
6. Remove front underbody panels to access chiller unit mounting area
7. Place coolant drain pan beneath chiller unit location
8. Connect refrigerant recovery machine to service ports on chiller unit

Procedure

1. 1

   Recover refrigerant from system
   Using certified refrigerant recovery equipment, connect to the high and low side service ports on the chiller unit. Follow recovery machine manufacturer instructions to fully evacuate all refrigerant from the system. Record the amount of refrigerant recovered for recharge reference. Ensure recovery is complete before proceeding.
2. 2

   Drain cooling system
   Locate the coolant drain valve on the chiller unit or associated cooling loop. Open the drain valve and allow coolant to drain into the collection pan. To facilitate complete drainage, open the coolant reservoir cap. Expect approximately 8-10 quarts of coolant to drain. Once flow stops, close drain valve.
3. 3

   Disconnect electrical connectors
   Locate the main electrical connector on the chiller unit (typically a weatherproof multi-pin connector). Press the connector lock tab and carefully pull the connector straight off. Identify and disconnect any temperature sensor connectors and pressure sensor connectors attached to the chiller. Secure connectors away from work area to prevent contamination.
4. 4

   Disconnect refrigerant lines
   Using appropriate refrigerant line disconnect tools, disconnect the high-pressure and low-pressure refrigerant lines from the chiller unit. Cap all open refrigerant ports immediately using service caps to prevent moisture ingress and contamination. Remove and discard all O-rings from the connection fittings.
5. 5

   Disconnect coolant lines
   Identify the inlet and outlet coolant hoses connected to the chiller unit. Using appropriate tools, loosen the coolant line connection fittings (typically quick-disconnect or threaded fittings). Be prepared for residual coolant spillage. Disconnect both coolant lines and cap the open ports on both the chiller and the lines. Remove and inspect sealing washers for damage.
6. 6

   Remove chiller mounting brackets
   Locate all mounting bolts securing the chiller unit to the vehicle chassis or underbody structure. Typically there are 4-6 mounting bolts. Support the weight of the chiller unit with one hand or a suitable support while removing the mounting hardware. Remove all mounting bolts and brackets, keeping hardware organized for reinstallation.
7. 7

   Remove chiller unit from vehicle
   With all connections and mounting hardware removed, carefully lower the chiller unit from its mounting position. The unit weighs approximately 25-35 lbs. Maneuver the unit clear of surrounding components and wiring harnesses. Remove the unit from beneath the vehicle and place on clean work surface.
8. 8

   Prepare new chiller unit
   Unpack the new chiller unit and verify part number matches application. Install new O-rings on all refrigerant line connection points, lightly lubricating with refrigerant oil. Install new sealing washers on coolant line connection points. Inspect all mounting bracket locations on the new unit and remove any shipping caps from ports.
9. 9

   Install new chiller unit
   Position the new chiller unit beneath the vehicle and maneuver into mounting location. Align the unit with mounting bracket holes on the chassis. Install mounting bolts hand-tight initially to allow for alignment adjustment. Once all bolts are started, tighten mounting bolts in a cross-pattern sequence. Final tightening torque should be confirmed with Rivian service documentation.
10. 10

    Reconnect coolant lines
    Connect the coolant inlet and outlet lines to the new chiller unit, ensuring proper routing and no kinks in lines. Thread or snap connections into place, verifying sealing washers are properly seated. Tighten threaded connections to specified torque (refer to Rivian service documentation for specific values). Verify connections are secure and properly oriented.
11. 11

    Reconnect refrigerant lines
    Remove service caps from refrigerant ports. Connect the high-pressure and low-pressure refrigerant lines to the appropriate ports on the new chiller unit. Ensure connections click or seat fully. Tighten refrigerant line fittings to specified torque to prevent leaks. Verify all O-rings remained in position during connection.
12. 12

    Reconnect electrical connections
    Route the main electrical harness connector to the chiller unit and press firmly until the connector lock clicks into place. Reconnect all temperature sensor and pressure sensor connectors, ensuring proper seating. Verify no pins are bent or damaged in any connectors.
13. 13

    Vacuum and recharge refrigerant system
    Connect vacuum pump to the refrigerant system service ports. Pull vacuum on the system for minimum 45 minutes to remove all moisture and air. System should hold vacuum without loss for at least 15 minutes to verify no leaks. Once vacuum test passes, recharge system with the amount of refrigerant recovered earlier (or per manufacturer specification if different). Use electronic scales to ensure accurate charge quantity.
14. 14

    Refill and bleed cooling system
    Using appropriate EV Battery/Motor Coolant, refill the cooling system through the reservoir. Connect Rivian diagnostic tool and initiate the cooling system bleeding procedure, which will cycle pumps to purge air from the system. Add coolant as needed during bleeding process until system is full and no air bubbles are present. Verify coolant level is at proper mark when system is fully bled.

Reassembly

1. Reinstall front underbody panels, ensuring all fasteners are properly torqued
2. Lower vehicle from jack stands to ground
3. Reconnect 12V auxiliary battery negative terminal
4. Reinstall HV disconnect following manufacturer procedures and remove lockout tag

Verification

• Using Rivian diagnostic tool, clear any stored fault codes and verify no active cooling system errors
• Start vehicle and allow thermal management system to activate
• Monitor coolant temperature readings on scan tool to verify chiller is functioning
• Inspect all refrigerant and coolant connections for leaks while system is operating
• Verify coolant level remains stable after initial operation cycle
• Test drive vehicle and monitor thermal system performance under normal operating conditions
• Perform final leak check of refrigerant system using electronic leak detector
• Verify cooling system can maintain proper battery and motor temperatures under load

More procedures for this vehicle