This procedure covers removal and replacement of the radiator (coolant heat exchanger) on the 2024 Rivian EDV 500 electric delivery van, including draining the EV cooling system and refilling with specified coolant.

Warnings

Tools required

Parts

• Radiator assembly (coolant heat exchanger) × 1 — Use OEM Rivian specification
• Upper radiator hose × 1 — Inspect and replace if damaged
• Lower radiator hose × 1 — Inspect and replace if damaged
• Hose clamps × 4 — OEM spring clamps or worm-drive 40-60mm
• Radiator mount bushings × 4 — Inspect and replace if worn
• Drain petcock seal × 1 — Usually included with radiator

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Ensure cooling system is completely cool to the touch (minimum 2 hours after operation)
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
4. Access and disconnect high-voltage system using Rivian service mode procedure (refer to service manual for HV interlock removal)
5. Remove front skid plate or underbody panel to access radiator drain and lower mounting points
6. Raise and support vehicle on jack stands at factory lift points
7. Remove front fascia lower section and grille assembly for radiator access
8. Place coolant drain pan beneath radiator drain petcock location

Procedure

1. 1

   Drain cooling system
   Locate the drain petcock at the bottom of the radiator on the driver side. Slowly turn the petcock counterclockwise by hand to open. Allow coolant to drain completely into the drain pan. Once drained, remove the coolant reservoir cap to allow complete drainage and equalize pressure.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Disconnect coolant hoses
   Using hose clamp pliers, release the upper radiator hose clamp at the radiator inlet. Slide the clamp back on the hose at least 2 inches. Twist the hose gently to break the seal, then pull straight off the radiator nipple. Repeat for the lower radiator hose at the radiator outlet. Allow any remaining coolant to drain.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect auxiliary cooling lines
   Locate the smaller auxiliary coolant lines running to the battery cooling circuit on the passenger side of the radiator. Using a flare nut wrench or appropriate tool, disconnect these lines. Have a rag ready to catch residual coolant. Cap or plug open lines to prevent contamination.
   ⚠These lines may contain residual pressure even after draining. Loosen slowly to relieve pressure gradually.
4. 4

   Disconnect cooling fan electrical connectors
   Locate the electric cooling fan module mounted to the back of the radiator. Press the locking tab and disconnect the main fan power connector. If equipped with dual fans, disconnect both connectors. Ensure no wiring is trapped or under tension.
   ℹ️On EDV 500, cooling fans are typically part of the radiator assembly and will be removed together.
5. 5

   Remove upper radiator mounting brackets
   Locate the two upper radiator mounting brackets secured to the radiator support. Remove the mounting bolts using a 10mm socket. Support the radiator with one hand while removing the final bolts to prevent it from shifting.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
6. 6

   Remove lower radiator mounts
   From underneath the vehicle, locate the lower radiator mounting tabs that sit in rubber isolator bushings. Remove the bolt or clip securing each lower mount. Note the orientation of any bushings or spacers for correct reinstallation.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
7. 7

   Remove radiator assembly
   Carefully tilt the top of the radiator toward the engine bay while lifting upward to clear the lower mounting pins. Guide the radiator up and out of the vehicle, being careful not to damage the cooling fins on surrounding components. If equipped, the cooling fan assembly will come out attached to the radiator. Have an assistant help if needed as the assembly can be awkward to maneuver.
   ⚠Radiator fins are fragile. Avoid contact with sharp edges or tools that could damage the cooling fins.
8. 8

   Inspect and prepare new radiator
   Inspect all mounting bushings and brackets on the new radiator. If the cooling fans were attached to the old radiator, transfer them to the new unit if not included. Install new rubber isolator bushings in the lower mounting points. Verify the drain petcock is closed on the new radiator.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
9. 9

   Install new radiator assembly
   Guide the new radiator into position from above, aligning the lower mounting pins with their isolator bushings. Ensure the radiator sits flush and level in the mounting position. Install lower mount fasteners finger-tight first to ensure proper alignment.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
10. 10

    Secure radiator mounting
    Install the upper radiator mounting brackets and bolts. Torque all radiator mounting bolts to specification using a torque wrench. Work in a crosswise pattern to ensure even mounting pressure. Do not overtighten as the mounting points are plastic and can crack.
    ⚠Plastic radiator tanks and mounting points are easily damaged by overtightening. Use a torque wrench and do not exceed specified torque.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect coolant hoses
    Inspect hose ends for cracks or deterioration and replace if necessary. Slide new hose clamps onto each hose. Push the upper radiator hose firmly onto the radiator inlet until it bottoms against the bead. Position the clamp 1/4 inch from the hose end and tighten to specification. Repeat for the lower radiator hose.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reconnect auxiliary cooling lines
    Remove caps or plugs from auxiliary coolant lines. Connect the auxiliary coolant lines to the radiator fittings, ensuring threads are clean and not cross-threaded. Torque to specification if applicable, or hand-tighten compression fittings as per factory specification.
    ℹ️Some auxiliary connections may use quick-disconnect fittings. Ensure you hear or feel a positive click when connecting.
13. 13

    Reconnect electrical connectors
    Reconnect all cooling fan electrical connectors, ensuring they click securely into place. Verify connector locks are fully engaged and no pins are bent or damaged.
14. 14

    Refill cooling system
    Close the drain petcock by turning clockwise hand-tight only. Fill the cooling system with the specified EV Battery/Motor Coolant through the coolant reservoir. Fill slowly to allow air to escape. Fill to the cold fill line on the reservoir. Install the reservoir cap. With the 12V battery connected and HV system still disabled, turn the ignition to ON and activate the coolant pump through the service menu if available to help purge air.
    ⚠Use only the specified EV-grade coolant. Standard automotive coolant may not be electrically non-conductive and could pose an electrical hazard.
    Torque spec

    Drain Petcock5 Nm (4 lb-ft)
15. 15

    Bleed cooling system
    Locate any coolant bleed valves on the system high points (typically near the coolant reservoir or battery pack connections). Open bleed valves and continue adding coolant until air-free coolant flows from the bleeder. Close bleed valves. Top off coolant reservoir to the cold fill line. The EDV 500 may have an automatic bleeding function accessible through service mode - consult service manual for vehicle-specific bleeding procedure.
    ℹ️EV cooling systems can trap air pockets that affect battery thermal management. Proper bleeding is critical for system performance and battery longevity.

Reassembly

1. Reinstall front underbody panels and skid plate, ensuring all clips and fasteners are secure
2. Reinstall front fascia lower section and grille assembly in reverse order of removal
3. Reconnect high-voltage system following Rivian service procedures and restore service mode settings
4. Reconnect 12V auxiliary battery negative terminal
5. Lower vehicle from jack stands

Verification

• With vehicle still on level ground, start the vehicle and allow cooling system to reach operating temperature
• Monitor coolant temperature through vehicle display or service software to verify proper operation
• Check for coolant leaks at all hose connections, auxiliary line connections, and radiator seams
• Verify cooling fans activate when system reaches operating temperature
• Allow vehicle to complete a full thermal cycle, then recheck coolant level when cool and top off if necessary
• Check for fault codes related to cooling system using diagnostic software
• Test drive vehicle and monitor battery and motor temperatures to ensure proper cooling performance
• After 50-100 miles of driving, recheck coolant level and inspect all connections for signs of leakage

More procedures for this vehicle