Cooling Fan Motor

This procedure covers the removal and replacement of the cooling fan motor in the Rivian EDV 500's thermal management system, which maintains proper operating temperatures for the battery pack and electric drive motors.

Warnings

Tools required

Parts

• Cooling fan motor assembly × 1 — Use OEM specification
• Fan motor mounting gasket/seal × 1 — Use OEM specification
• Electrical connector seal × 1 — Use OEM specification
• Coolant hose clamps × 2 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from vicinity of vehicle
3. Open the high voltage service disconnect located under the rear cargo area access panel
4. Wait minimum 5 minutes for high voltage capacitors to discharge
5. Verify zero voltage at high voltage system using appropriate meter and safety procedures
6. Place 'DO NOT OPERATE' warning tag on service disconnect
7. Allow cooling system to cool to ambient temperature (minimum 2 hours if vehicle was recently operated)
8. Connect diagnostic tool and record any existing fault codes related to thermal management
9. Remove front underbody shield to access cooling system components
10. Position coolant drain pan beneath cooling system drain point

Procedure

1. 1

   Drain cooling system
   Locate the cooling system drain valve on the lower section of the front thermal management module. Attach drain hose to valve and route into drain pan. Open drain valve and allow coolant to drain completely. Note the color and condition of coolant for contamination assessment. Close drain valve when fully drained.
2. 2

   Remove front fascia lower section
   Remove the lower front fascia panel by releasing the plastic clips along the bottom edge. Use trim removal tools to avoid breaking clips. Disconnect any ambient temperature sensors or wiring connected to the removed panel. Set panel aside in protected area.
3. 3

   Access cooling fan assembly
   Locate the cooling fan motor assembly mounted in the front thermal management enclosure. Remove the protective cover by removing the Torx fasteners securing it to the enclosure. The fan motor will be visible with electrical connector on top and coolant lines on the sides.
4. 4

   Disconnect electrical connector
   Depress the locking tab on the cooling fan motor electrical connector. Carefully pull connector straight away from motor. Inspect connector pins for corrosion or damage. If connector seal shows wear, mark for replacement.
5. 5

   Disconnect coolant lines
   Using appropriate pliers, release the spring clamps on both coolant hoses connected to the fan motor housing. Have a small container ready as residual coolant will drain from the connections. Slide hoses off the fan motor ports. Cap or plug the open coolant lines to prevent contamination.
6. 6

   Remove fan motor mounting fasteners
   Remove the mounting bolts securing the cooling fan motor to the thermal management enclosure. There are typically three or four mounting points around the perimeter of the motor housing. Support the motor assembly as you remove the final fastener to prevent it from dropping.
7. 7

   Remove cooling fan motor
   Carefully extract the cooling fan motor assembly from the thermal management enclosure. Tilt and rotate as necessary to clear surrounding components. Inspect the mounting surface and gasket seating area for damage or debris. Clean the mounting surface thoroughly with lint-free cloths.
8. 8

   Inspect and prepare new fan motor
   Compare the new cooling fan motor to the removed unit to verify correct part. Install new mounting gasket/seal onto the new motor assembly. Verify that the electrical connector and coolant port configuration matches the original. Check that coolant ports are clear of any shipping plugs or protective covers.
9. 9

   Install new cooling fan motor
   Position the new cooling fan motor into the thermal management enclosure, aligning the mounting holes with the threaded bosses. Ensure the gasket remains properly seated during installation. Start all mounting fasteners by hand before tightening to ensure proper alignment. Tighten mounting fasteners in a cross pattern to ensure even gasket compression. Note: No specific torque values available, tighten securely per manufacturer assembly procedures.
10. 10

    Reconnect coolant lines
    Remove protective caps from coolant lines. Inspect hose ends for cuts or deterioration and replace if necessary. Slide coolant hoses fully onto the fan motor ports until they bottom out. Install new spring clamps or reuse original clamps if in good condition. Ensure clamps are positioned correctly over the connection barbs.
11. 11

    Reconnect electrical connector
    Inspect the electrical connector for any debris in the socket. Align connector with motor and press firmly until the locking tab clicks into place. Gently tug on connector to verify it is fully locked. If new connector seal was required, verify it is properly seated.
12. 12

    Refill cooling system
    Using Rivian-specified EV Battery/Motor Coolant, refill the cooling system through the fill port. Fill slowly to minimize air pocket formation. Add coolant until level reaches the full mark on the expansion tank. Do not overfill. Refer to fluid specifications: approximately 2 quarts will be needed to replace drained coolant, though full system capacity is 10 quarts.
13. 13

    Bleed cooling system
    With the cooling system filled, activate the cooling system bleed procedure using the Rivian diagnostic tool. This will cycle the coolant pumps and run the fan motor to purge air from the system. Monitor coolant level during bleeding and add coolant as necessary. Continue bleeding until no air bubbles are visible in the expansion tank and coolant level remains stable.
14. 14

    Test cooling fan operation
    Using the diagnostic tool, command the cooling fan motor to operate at various speeds (low, medium, high). Verify smooth operation with no unusual noises, vibrations, or binding. Check for coolant leaks at all connection points while fan is operating. Monitor fan current draw on diagnostic tool to verify it is within specifications.
15. 15

    Reinstall protective components
    Reinstall the thermal management enclosure protective cover with Torx fasteners. Reinstall the front fascia lower section, ensuring all clips are properly engaged and any sensors are reconnected. Reinstall front underbody shield. Clear any diagnostic trouble codes related to the fan motor replacement procedure.

Reassembly

1. Verify all fasteners are tightened and all electrical connections are secure
2. Confirm coolant level is at the proper mark on expansion tank with system at ambient temperature
3. Reconnect high voltage service disconnect and remove lockout/tagout warning tag
4. Clear the service disconnect fault code using diagnostic tool
5. Verify no coolant leaks are present at fan motor connections or drain valve

Verification

• Start vehicle and allow thermal management system to reach normal operating mode
• Use diagnostic tool to verify cooling fan motor responds to all commanded speed requests
• Monitor coolant temperature to ensure it remains within normal operating range
• Verify no new fault codes are present in the thermal management system
• Perform a test drive and confirm cooling system maintains proper temperatures under load
• Recheck coolant level after test drive and top off if necessary
• Inspect all connection points for coolant leaks after system has been under pressure
• Verify cooling fan motor current draw matches specification when operating at full speed

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