Cooling Fan Assembly

This procedure covers the removal and replacement of the cooling fan assembly on a 2025 Rivian EDV 500 dual motor electric delivery van, including the radiator-mounted cooling fan used for battery and motor thermal management.

Warnings

Tools required

Parts

• Cooling fan assembly × 1 — Use OEM specification
• Cooling fan wiring harness (if damaged) × 1 — Use OEM specification
• Radiator hose clamps × 2 — Use OEM specification
• Coolant reservoir cap seal × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Turn off the vehicle and remove the key fob from the cabin
3. Wait at least 10 minutes for high voltage system capacitors to discharge
4. Open the front access panel and locate the 12V service disconnect
5. Disconnect the 12V battery using the service disconnect switch located in the front compartment
6. Place warning tags on the driver's seat indicating high voltage work in progress
7. Allow cooling system to cool to ambient temperature (minimum 2 hours after last operation)
8. Verify coolant temperature is below 100°F before proceeding
9. Raise and support the front of the vehicle on jack stands if lower access is required
10. Remove the front fascia lower shield to access cooling system components

Procedure

1. 1

   Access the cooling fan assembly
   Remove the front grille assembly by releasing the retaining clips along the top edge. Disconnect the front sensor wiring harness if equipped with front parking sensors. Remove the upper radiator shroud by removing the fasteners along the top edge. Store all fasteners in an organized manner for reassembly.
2. 2

   Depressurize the cooling system
   Slowly loosen the coolant reservoir cap one full turn to release any residual pressure. Listen for hissing sounds indicating pressure release. Once pressure is fully released, remove the cap completely. Place a drain pan beneath the lower radiator area to catch coolant spillage.
3. 3

   Disconnect electrical connections
   Locate the cooling fan motor electrical connector on the driver's side of the fan shroud. Press the locking tab and disconnect the main power connector. Disconnect the secondary sensor connector if equipped with variable speed control. Verify no voltage is present using a multimeter if available. Tag connectors for proper reassembly.
4. 4

   Drain coolant from the system
   Locate the radiator drain petcock on the lower passenger side of the radiator. Open the drain valve and allow coolant to drain into the collection pan. Expect approximately 1-2 quarts to drain. Keep drained coolant separate for inspection and potential reuse if clean and within service life.
5. 5

   Disconnect upper coolant hose
   Locate the upper radiator hose connection point near the fan assembly. Use pliers to compress and slide the spring clamp away from the connection point. Carefully twist and pull the hose to separate it from the radiator inlet. Be prepared for additional coolant spillage. Inspect the hose for cracks or deterioration.
6. 6

   Remove fan shroud mounting bolts
   Locate the four mounting bolts securing the fan shroud assembly to the radiator support. Remove the upper two bolts first while supporting the fan assembly. Remove the lower two bolts while maintaining support of the assembly. The fan assembly is integrated with the shroud and weighs approximately 15-20 pounds.
7. 7

   Extract the cooling fan assembly
   Carefully tilt the top of the fan assembly toward the engine compartment to clear the radiator mounting tabs. Lift the assembly upward and out of the engine bay, being careful not to damage the radiator fins or other components. Inspect the fan blades for damage, cracks, or missing pieces. Check the motor bearings by spinning the fan blade by hand - it should rotate smoothly without binding or grinding.
8. 8

   Inspect radiator and mounting points
   With the fan assembly removed, inspect the radiator face for debris, damage, or fin deformation. Clean any accumulated debris from the radiator core using compressed air from the engine side outward. Inspect the four mounting bosses on the radiator for cracks or damage. Check rubber isolation mounts for deterioration and replace if necessary.
9. 9

   Install new cooling fan assembly
   Position the new cooling fan assembly above the radiator, aligning the lower mounting tabs first. Tilt the assembly into position, ensuring proper seating on the radiator support brackets. Hand-thread all four mounting bolts before tightening. Tighten mounting bolts in a cross pattern to ensure even pressure distribution. Since no torque specification is provided, tighten securely but do not over-torque plastic components.
10. 10

    Reconnect upper coolant hose
    Position the upper radiator hose onto the radiator inlet, ensuring it is fully seated. Slide the spring clamp back into position over the connection point. Verify the clamp is positioned correctly in the hose bead groove. Tug gently on the hose to confirm secure attachment.
11. 11

    Reconnect electrical connections
    Connect the cooling fan motor main power connector, ensuring the locking tab clicks into place. Connect the secondary sensor connector if applicable. Verify connections are secure by gently pulling on each connector. Remove any identification tags applied during disassembly.
12. 12

    Refill cooling system
    Close the radiator drain petcock securely. Using a funnel, slowly add EV Battery/Motor Coolant to the coolant reservoir until it reaches the MAX cold fill line. Add coolant slowly to minimize air pocket formation. Do not overfill as coolant will expand when the system reaches operating temperature.
13. 13

    Bleed cooling system
    With the coolant reservoir cap removed, reconnect the 12V service disconnect. Turn the vehicle to ON mode without engaging drive. Allow the cooling fan to cycle through its self-test procedure. Add additional coolant as needed as air pockets are purged from the system. The coolant level will drop as air is displaced. Continue until the level stabilizes at the MAX cold fill line.
14. 14

    Reinstall shrouds and panels
    Install the upper radiator shroud and secure with the original fasteners. Reconnect any sensor wiring harnesses. Install the front grille assembly, ensuring all retaining clips are fully engaged. Install the lower front fascia shield. Verify all panels are secure and properly aligned.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify coolant level is at the MAX cold fill line on the reservoir
3. Confirm all panels, shields, and grille components are reinstalled
4. Remove warning tags from the vehicle
5. Double-check that no tools or parts were left in the engine compartment

Verification

• Reconnect the 12V service disconnect if not already done
• Turn the vehicle to ON mode and observe the instrument cluster for any cooling system warning lights or messages
• Allow the vehicle to run through a complete cooling fan cycle - the fan should activate and operate smoothly without unusual noise or vibration
• Check for coolant leaks around the radiator hose connection and fan mounting area
• Use a Rivian diagnostic tool to verify no fault codes are present in the thermal management system
• Test drive the vehicle for at least 15 minutes, monitoring the coolant temperature gauge for normal operation
• After the test drive, recheck coolant level when the system has cooled and top off to the MAX cold fill line if necessary
• Verify the cooling fan activates during normal driving conditions when thermal management is required
• Monitor vehicle performance over the next several days to ensure proper cooling system operation and no loss of coolant

More procedures for this vehicle