This procedure covers the removal and replacement of the blower motor assembly in the HVAC system of a 2025 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• HVAC Blower Motor Assembly × 1 — Use OEM specification
• Blower Motor Resistor (if damaged) × 1 — Use OEM specification
• Trim panel clips (if broken) × 1 — Rivian trim clip assortment

Preparation

1. Park the vehicle on level ground and engage the parking brake
2. Turn off all vehicle systems and allow the HVAC system to fully power down (wait 2 minutes)
3. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Remove any floor mats or cargo debris from the passenger footwell area
5. Position adequate lighting to illuminate the passenger footwell and lower dash area
6. Take photos of the lower dash panel and wiring routing for reference during reassembly

Procedure

1. 1

   Remove passenger lower dash panel
   Using the trim panel removal tools, carefully pry out the passenger side lower dash trim panel. Start from the bottom edge and work around the perimeter. Remove four T20 Torx screws securing the panel, then disconnect any ambient lighting connectors before fully removing the panel. Set the panel and fasteners aside in a safe location.
2. 2

   Access blower motor housing
   Locate the blower motor housing in the lower HVAC plenum on the passenger side. Remove the sound insulation foam pad if present by releasing the retaining clips. Use a shop vacuum to clean any debris around the blower motor housing to prevent contamination during removal.
3. 3

   Disconnect blower motor resistor
   Locate the blower motor resistor module attached to the blower motor housing. Press the locking tab and disconnect the electrical connector from the resistor. Remove the two screws securing the resistor to the housing using a T20 Torx driver, applying torque as specified. Inspect the resistor for signs of overheating or damage.
   Torque spec

   Blower Motor Resistor Screws2 Nm (1.5 lb-ft)
4. 4

   Disconnect blower motor electrical connector
   Locate the main blower motor electrical connector. Press the red locking tab while gently pulling the connector straight away from the motor. Do not pull on the wiring harness. If the connector is difficult to remove, use needle nose pliers to depress the locking tab while pulling.
5. 5

   Remove blower motor mounting screws
   Identify the three T30 Torx screws securing the blower motor assembly to the HVAC housing. The screws are positioned around the perimeter of the motor flange. Remove all three screws completely and retain them for reinstallation. Note that one screw may be located at the top of the motor and difficult to access.
   Torque spec

   Blower Motor Screws4 Nm (3 lb-ft)
6. 6

   Remove blower motor assembly
   Carefully rotate the blower motor assembly counterclockwise approximately 30 degrees to disengage it from the housing alignment tabs. Gently pull the motor assembly straight down and out of the HVAC housing. The fan wheel will come out with the motor. Support the assembly to prevent dropping it.
7. 7

   Inspect and clean HVAC housing
   With the blower motor removed, inspect the HVAC housing opening for debris, leaves, or moisture. Use a shop vacuum to remove any contamination. Check the housing seal surface for damage. Inspect the removed blower motor for signs of bearing failure, unusual wear, or debris lodged in the fan wheel.
8. 8

   Install new blower motor assembly
   Position the new blower motor assembly with the electrical connector facing the correct orientation as documented in your reference photos. Insert the motor into the HVAC housing opening, aligning the mounting flange with the housing. Rotate clockwise 30 degrees to engage the alignment tabs. Ensure the motor seats fully against the housing.
9. 9

   Install blower motor mounting screws
   Install the three T30 Torx mounting screws through the motor flange into the HVAC housing. Start all three screws by hand before tightening. Using a torque wrench, tighten the screws in a star pattern to the specified torque value to ensure even sealing pressure.
   Torque spec

   Blower Motor Screws4 Nm (3 lb-ft)
10. 10

    Reconnect blower motor electrical connector
    Align the blower motor electrical connector with the motor terminal and push firmly until the red locking tab clicks into place. Verify the connection is secure by gently pulling on the connector body, not the wiring.
11. 11

    Reinstall blower motor resistor
    Position the blower motor resistor module onto the mounting location on the blower motor housing. Install the two T20 Torx screws and tighten to the specified torque. Reconnect the resistor electrical connector, ensuring the locking tab engages fully.
    Torque spec

    Blower Motor Resistor Screws2 Nm (1.5 lb-ft)
12. 12

    Reinstall sound insulation and lower dash panel
    Replace the sound insulation foam pad if removed, ensuring all retaining clips are properly engaged. Reconnect any ambient lighting connectors to the lower dash panel. Position the panel and install the four T20 Torx screws. Press firmly around the panel perimeter to engage all trim clips.

Reassembly

1. Ensure all electrical connectors are fully seated and locked before powering the system
2. Verify no tools or fasteners have been left in the dash or footwell area
3. Replace any trim clips that were damaged during disassembly
4. Reconnect the 12V battery negative terminal and ensure it is securely tightened

Verification

• Power on the vehicle and enter the HVAC menu on the touchscreen display
• Test blower motor operation at all speed settings (1 through 10) to verify proper function
• Listen for any unusual noises such as squealing, grinding, or vibration from the blower motor area
• Verify airflow is consistent and strong at maximum speed from all dash vents
• Check for proper air distribution in all modes (floor, panel, defrost, mixed)
• Confirm no air leaks are audible around the lower dash panel
• Verify cabin temperature control responds properly with the new blower motor installed
• Test HVAC system in both heating and cooling modes to ensure full functionality
• Clear any diagnostic trouble codes related to blower motor malfunction if present

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