This procedure covers the removal and replacement of the EV coolant lines that circulate coolant to the battery pack, electric motors, and power electronics on the 2024 Rivian EDV 500.

Warnings

Tools required

Parts

• EV coolant lines (as needed) × 1 — Use OEM specification
• Quick disconnect O-rings × 8 — Use OEM specification
• Coolant line clamps × 4 — Use OEM specification
• Underbody panel clips × 10 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Connect Rivian diagnostic software and verify no active drive system faults
3. Access HV battery service disconnect using manufacturer procedure and verify de-energization with appropriate HV test equipment
4. Install HV lockout tag and store service disconnect key in your possession
5. Allow coolant system to cool for minimum 2 hours after last vehicle operation
6. Raise vehicle on lift to comfortable working height
7. Remove front and rear underbody panels to access coolant routing
8. Place absorbent pads under coolant line work areas
9. Position drain pan under coolant reservoir and drain points

Procedure

1. 1

   Depressurize and drain coolant system
   Slowly open the coolant reservoir cap to release any residual pressure. Using diagnostic software, access the thermal management menu and initiate coolant drain procedure if available. Otherwise, locate the coolant drain valve on the underside of the battery pack (driver side, mid-pack location) and open to drain coolant into collection pan. Drain coolant from expansion tank.
2. 2

   Document coolant line routing
   Take detailed photographs of coolant line routing, including connection points, clip locations, and relationship to other components. Pay special attention to lines running to front drive unit, rear drive unit, battery pack, and inverter assembly. Note any identification labels or colored markings on lines.
3. 3

   Disconnect coolant lines from front drive unit
   Locate the coolant supply and return lines connected to the front drive unit thermal jacket. Use quick disconnect tool to release the locking mechanism on each fitting. Gently twist and pull the lines to separate. Cap open connections immediately with plugs to prevent contamination. Inspect O-rings for damage and replace if necessary.
4. 4

   Disconnect coolant lines from rear drive unit
   Access the rear drive unit coolant connections from underneath the vehicle. Release quick disconnect fittings using appropriate tool. The rear unit typically has two coolant lines connected to the motor housing. Remove lines and cap all openings. Allow residual coolant to drain into collection pan.
5. 5

   Disconnect battery pack thermal lines
   Locate the battery pack coolant inlet and outlet connections on the battery enclosure (typically passenger side). These connections are critical to battery thermal management. Use caution when releasing quick disconnect fittings as they may have higher spring tension. Remove lines and immediately cap connections to prevent debris entry.
6. 6

   Disconnect inverter and electronics cooling lines
   Access power electronics cooling connections at the inverter assembly located in the front compartment. Release quick disconnect fittings for both supply and return lines. Note that electronics cooling circuit may be separate from motor cooling circuit. Cap all openings.
7. 7

   Release coolant line securing clips and brackets
   Work along the length of each coolant line being replaced, releasing all securing clips, brackets, and cable ties. The lines are typically secured at 18-24 inch intervals along frame rails and under battery pack. Use trim tools to release push clips without breaking. Keep all hardware organized for reinstallation.
8. 8

   Remove coolant lines from vehicle
   Carefully extract coolant lines from vehicle, working from front to rear or vice versa as access allows. Lines may be routed through tight spaces between battery pack and body structure. Avoid pulling or forcing lines as adjacent wiring harnesses or other components may be in contact. Inspect removed lines for wear, chafing, or damage to determine root cause of failure.
9. 9

   Prepare new coolant lines for installation
   Unpack new coolant lines and verify part numbers match application. Inspect all quick disconnect fittings for proper O-ring installation. Apply light film of approved EV coolant to O-rings for easier installation. Compare new lines to removed lines to verify routing and length before installation.
10. 10

    Install new coolant lines
    Route new coolant lines through vehicle following documented original path. Ensure lines are not twisted, kinked, or in contact with sharp edges. Maintain minimum 1 inch clearance from exhaust components if applicable. Work lines through frame channels and secure with original clips and brackets as you progress. Ensure adequate clearance from suspension components through full range of motion.
11. 11

    Connect coolant lines to all components
    Working systematically, connect coolant lines to battery pack, front drive unit, rear drive unit, and power electronics. Push each quick disconnect fitting firmly until you hear and feel the positive click engagement. Verify each connection by attempting to pull line away from fitting - properly connected lines will not separate. Double-check that supply and return lines are connected to correct ports.
12. 12

    Refill coolant system
    Close all drain valves. Fill coolant reservoir with fresh EV Battery/Motor Coolant to MAX mark. Using diagnostic software, access thermal management system and initiate coolant fill/bleed procedure if available. This will cycle pumps to purge air from system. If manual bleeding is required, run pumps and add coolant as level drops in reservoir. Continue until no air bubbles are visible and level stabilizes.
13. 13

    Pressure test coolant system
    If available, connect coolant pressure tester to reservoir and pressurize system to 15 PSI. Allow to sit for 10 minutes and monitor for pressure drop. Inspect all new connections for leaks using shop light. If pressure holds and no leaks are observed, system is sealed properly. If diagnostic software is used, it may perform automated pressure test.
14. 14

    Reinstall underbody panels and restore vehicle
    Reinstall all underbody panels and aero shields using new clips where necessary. Ensure all panels are securely fastened and properly aligned. Reinstall HV battery service disconnect per manufacturer procedure. Using diagnostic software, clear any thermal management fault codes that may have been set during service. Remove HV lockout tag.

Reassembly

1. Ensure all coolant line connections are fully seated and locked
2. Verify coolant level is at MAX mark on reservoir after system stabilization
3. Confirm all securing clips and brackets are properly installed along entire coolant line routing
4. Verify underbody panels are secure and not interfering with coolant lines

Verification

• Using diagnostic software, activate thermal management system and verify coolant circulation through all circuits
• Monitor coolant temperature readings for all components (battery, motors, inverter) to verify proper flow
• Perform test drive including acceleration, regenerative braking, and sustained highway speed to exercise thermal system
• After test drive, inspect all coolant connections for leaks with vehicle on lift
• Check coolant level in reservoir - should remain at or near MAX mark
• Verify no thermal management fault codes are present in diagnostic system
• Confirm battery thermal management system can maintain target temperature range under load

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