Radiator Removal and Service

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

Warnings

Tools required

Parts

• Radiator/Heat Exchanger Assembly × 1 — Use OEM specification
• Radiator mounting grommets × 4 — Use OEM specification
• Coolant hose clamps × 4 — Use OEM specification
• Lower coolant drain plug seal × 1 — Use OEM specification
• O-rings for coolant quick-disconnect fittings × 4 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Ensure vehicle has been off and cooling for minimum 2 hours
2. Park vehicle on level surface and engage parking brake
3. Verify battery state of charge is below 80% for safety during service
4. Place wheel chocks at rear wheels
5. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
6. Verify high voltage system is de-energized using multimeter at service disconnect location
7. Remove front underbody panels to access coolant drain points
8. Document any error codes using diagnostic tool before beginning work

Procedure

1. 1

   Access High Voltage Service Disconnect
   Open the driver side rear cargo area access panel. Locate the high voltage service disconnect (orange-colored handle). Wearing insulated gloves, rotate the service disconnect counterclockwise 1/4 turn and pull to remove. Store in a secure location away from the vehicle. Wait 5 minutes for HV capacitors to discharge. Verify zero voltage across HV busbars using multimeter.
2. 2

   Drain Cooling System
   Position drain pan under the front center of the vehicle beneath the coolant drain plug location. Locate the coolant drain plug on the underside of the radiator assembly (driver side, forward of the front motor). Slowly open the drain plug to release pressure gradually, then remove completely once pressure is equalized. Allow coolant to drain completely (approximately 10 quarts). Remove the coolant reservoir cap to facilitate complete drainage.
3. 3

   Remove Front Fascia Lower Section
   Remove the lower front fascia panel by releasing 8 push-pin fasteners and 4 Torx screws (T30). Carefully pull the fascia forward to disengage the retention clips. Disconnect the ambient air temperature sensor connector if equipped. Set aside the fascia panel in a protected area to prevent damage.
4. 4

   Disconnect Cooling Fan Assembly
   Locate the dual cooling fan assembly mounted to the rear of the radiator. Disconnect the two electrical connectors from the fan motors (press release tabs and pull straight back). Remove the 4 fan shroud mounting bolts (10mm) securing the fan assembly to the radiator support brackets. Carefully lift the fan assembly up and out, routing the wiring harness clear of the radiator.
5. 5

   Disconnect Upper Coolant Hoses
   Locate the upper coolant inlet and outlet hoses connected to the top of the radiator. Using hose clamp pliers, compress and slide back the spring clamps on both hoses. Twist the hoses gently to break any seal, then pull straight off the radiator nipples. Have rags ready to catch residual coolant. Cap the open hose ends with plastic caps to prevent contamination.
6. 6

   Disconnect Lower Coolant Hoses
   From underneath the vehicle, locate the lower coolant hoses connecting to the radiator. These may be quick-disconnect style fittings. For quick-disconnect fittings, press the release collar and pull the line straight out. For hose clamp style, use hose clamp pliers to release the clamps and remove the hoses. Cap all open lines immediately.
7. 7

   Disconnect Transmission Cooler Lines
   Locate the EV transmission fluid cooler lines integrated into the radiator assembly (typically on passenger side). These use quick-disconnect fittings. Press the release buttons on each fitting and pull the lines straight out. Expect small amount of transmission fluid spillage. Cap the open fittings on both the lines and radiator to prevent contamination.
8. 8

   Remove Radiator Support Brackets
   Locate the upper radiator support brackets (typically 2 brackets, one on each side). Remove the mounting bolts (13mm) securing the brackets to the vehicle frame. The brackets may be separate from the radiator or integrated. If separate, remove them to provide clearance for radiator removal.
9. 9

   Release Radiator Mounting Points
   Identify the lower radiator mounting points. These typically consist of rubber grommets or bushings that the radiator tabs sit in. The radiator may also have side mounting brackets with bolts (10mm or 13mm). Remove any side mounting bolts. Note the orientation and position of all mounting hardware for reinstallation.
10. 10

    Remove Radiator Assembly
    With all connections and mounting hardware removed, carefully lift the radiator assembly straight up and out of the engine bay. The radiator is fragile - avoid bending or flexing the core. Guide it past any remaining wiring harnesses or brackets. Have an assistant help if needed as the assembly is bulky and awkward to maneuver. Place the radiator on a clean, protected surface with the core facing up.
11. 11

    Inspect and Service Radiator
    Inspect the radiator core for damage, leaks, or debris blockage. Check all connection points for cracks or damage. If servicing (cleaning) the radiator, use only approved EV coolant system cleaner - never use petroleum-based products. Inspect and replace all rubber mounting grommets, O-rings, and seals. If installing a new radiator, transfer any necessary brackets or sensors from the old unit.

Reassembly

1. Install radiator assembly by reversing removal steps, ensuring all mounting grommets are properly seated
2. Install all coolant hoses with new clamps or O-rings, ensuring proper orientation and full seating
3. Reconnect transmission cooler lines until they click into place
4. Torque all mounting bolts to manufacturer specifications when available
5. Reinstall cooling fan assembly and reconnect electrical connectors
6. Reinstall front fascia and underbody panels
7. Close coolant drain plug with new seal
8. Fill cooling system with specified EV Battery/Motor Coolant (10 quarts total capacity)
9. Bleed air from cooling system per manufacturer procedure
10. Reinstall high voltage service disconnect and rotate clockwise 1/4 turn to lock
11. Reconnect 12V battery negative terminal

Verification

• Using Rivian diagnostic tool, run thermal management system initialization and bleeding procedure
• Start vehicle and allow thermal management system to circulate coolant for 10 minutes
• Monitor coolant temperature and flow using diagnostic tool - verify normal operation
• Check all connection points for coolant leaks while system is operating
• Verify coolant level is at proper mark on reservoir after system reaches operating temperature
• Clear any stored fault codes and perform test drive
• Recheck coolant level after test drive and top off if necessary
• Verify cooling fan operation by observing activation during thermal management cycling
• Document completion and any error codes in service records

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