Cooling Fan Motor

This procedure covers the removal and replacement of the cooling fan motor assembly on the 2025 Rivian EDV 500 electric delivery van, which cools the battery pack and drive unit thermal management systems.

Warnings

Tools required

Parts

• Cooling fan motor assembly × 1 — Use OEM specification
• Fan motor wiring harness connector seal × 1 — Use OEM specification
• Coolant hose clamps × 2 — Use OEM specification
• Undertray fastener clips × 6 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off and cooling system cold for minimum 2 hours
3. Disconnect 12V battery negative terminal and wait 15 minutes
4. Place wheel chocks at rear wheels
5. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
6. Remove front undertray panels using Torx T30 and 8mm fasteners (retain clips for reinstallation)
7. Place coolant drain pan beneath cooling fan assembly area
8. Document or photograph coolant hose routing and electrical connector orientations

Procedure

1. 1

   Access cooling fan assembly
   Remove the front lower fascia access panel by releasing four push-pin retainers and one Torx T30 fastener. Carefully pull the panel forward and down to disengage the upper clips. Set aside with fasteners organized for reinstallation.
2. 2

   Disconnect cooling fan electrical connector
   Locate the cooling fan motor connector on the passenger side of the fan shroud. Press the orange locking tab upward and pull the connector straight back to disconnect. Use the wire terminal removal tool if the connector is resistant. Inspect the connector seal for damage.
3. 3

   Drain coolant from fan circuit
   Locate the coolant drain valve on the lower radiator inlet line near the fan assembly. Attach a drain hose and open the valve by rotating counterclockwise. Allow approximately 2 quarts of coolant to drain into the collection pan. Close the drain valve once flow stops.
   ⚠Verify coolant temperature is below 100°F before opening drain valve. Hot coolant under pressure can spray.
4. 4

   Disconnect coolant inlet hose
   Using needle-nose pliers, compress and slide the spring clamp on the upper coolant inlet hose back approximately 2 inches from the fan motor housing connection. Twist the hose gently while pulling to disconnect. Be prepared for residual coolant spillage. Cap or plug the hose end to prevent contamination.
5. 5

   Disconnect coolant outlet hose
   Repeat the disconnection process for the lower coolant outlet hose. Compress the spring clamp, slide it back, twist and pull the hose from the fan motor housing. Allow any remaining coolant to drain into the collection pan.
6. 6

   Remove fan assembly upper mounting bolts
   Using a 10mm socket with 6-inch extension, remove the two upper fan shroud mounting bolts accessible from above. These bolts secure the fan assembly to the front thermal management module. Support the fan assembly from below to prevent it from dropping.
7. 7

   Remove fan assembly lower mounting bolts
   From underneath the vehicle, remove the two lower 10mm mounting bolts that secure the fan assembly to the subframe brackets. Keep track of any spacers or washers on these bolts as they control fan positioning.
8. 8

   Remove fan assembly from vehicle
   Carefully guide the cooling fan assembly downward and forward out of the vehicle from underneath. Maneuver around the coolant lines and wiring harness. The assembly weighs approximately 8-10 pounds. Inspect the mounting grommets and brackets for wear or damage.
9. 9

   Install new cooling fan motor
   Position the new cooling fan assembly into the mounting location from underneath the vehicle. Align the mounting brackets with the subframe and thermal module mounting points. Ensure the fan shroud fits flush against the radiator or condenser interface.
10. 10

    Install mounting bolts
    Install the two lower 10mm mounting bolts with any spacers in their original positions. Hand-tighten initially. Install the two upper 10mm mounting bolts from above. Tighten all four bolts evenly in a cross pattern to ensure proper seating. Final tightening should be firm but not over-torqued as the shroud is plastic.
11. 11

    Reconnect coolant hoses
    Reconnect the lower coolant outlet hose to the fan motor housing, pushing firmly until it seats completely. Slide the spring clamp into position over the connection point. Repeat for the upper coolant inlet hose. Verify both hoses are fully seated and clamps are positioned correctly over the connection barbs.
12. 12

    Reconnect electrical connector
    Align and connect the cooling fan motor electrical connector, pushing until it clicks into place. Press the orange locking tab down to secure. Install the new connector seal if the original showed any damage. Gently tug on the connector to verify it is locked.
13. 13

    Refill cooling system
    Close the coolant drain valve completely. Using a funnel at the coolant reservoir, slowly add EV Battery/Motor Coolant to bring the level to the cold fill line. If using a vacuum refill tool, connect to the reservoir and follow manufacturer instructions to eliminate air from the system. Add approximately 2 quarts or as needed to reach proper level.
    ⚠Use only Rivian-approved EV coolant. Do not mix with conventional automotive coolant or water.
14. 14

    Bleed cooling system air
    With coolant reservoir cap removed, reconnect the 12V battery. Turn the vehicle to ON mode without ready-to-drive. Access the vehicle service menu through the center display and activate the cooling fan test function. Allow the fan to run for 2-3 minutes while monitoring coolant level. Add coolant as needed as air purges from the system. Turn vehicle off and install reservoir cap.

Reassembly

1. Reinstall front undertray panels using original fasteners and replace any damaged clips
2. Reinstall front lower fascia access panel, engaging upper clips first then securing lower fasteners
3. Lower vehicle from jack stands and remove wheel chocks
4. Top off coolant reservoir to cold fill line after vehicle has sat for 15 minutes
5. Dispose of used coolant according to local environmental regulations

Verification

• Reconnect 12V battery if disconnected for bleeding procedure
• Turn vehicle to ON mode and monitor for any cooling system warning lights on the instrument cluster
• Activate climate control to maximum cooling and listen for cooling fan operation - fan should engage smoothly without unusual noise
• Check all coolant connections for leaks while fan is running
• Allow vehicle to run for 10 minutes, then turn off and inspect coolant level - top off if needed
• Test drive vehicle and monitor battery and drive unit temperatures on the vehicle display to ensure proper thermal management
• Recheck coolant level after test drive when system is cold - level should remain at cold fill line
• Verify no warning lights or fault codes are present using vehicle diagnostics if available

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