This procedure covers the removal and replacement of the EV coolant pump on a 2025 Rivian EDV 500 Dual Motor AWD, including coolant system drainage, pump removal, and system refill with bleeding.

Warnings

Tools required

Parts

• EV coolant pump assembly × 1 — Use OEM Rivian specification
• Coolant pump O-ring seal × 1 — Use OEM specification
• Coolant hose clamps × 2 — Constant tension type
• High voltage connector seals × 1 — If damaged during removal

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off for at least 2 hours to allow coolant system to cool completely
3. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
4. Access high voltage service disconnect located under rear seat area and remove service plug
5. Wait 10 minutes after removing HV disconnect for capacitor discharge
6. Use multimeter to verify high voltage system is de-energized at HV battery terminals
7. Raise vehicle and secure on jack stands at manufacturer-specified lift points
8. Remove front undertray panels to access coolant pump location
9. Place drain pan under vehicle beneath coolant pump area

Procedure

1. 1

   Drain coolant system
   Locate the coolant drain valve on the lower coolant reservoir beneath the front trunk area. Attach drain hose to valve and route to drain pan. Open drain valve completely and allow system to drain for at least 15 minutes. The system holds approximately 10 quarts of coolant.
2. 2

   Disconnect coolant pump electrical connector
   Locate the coolant pump electrical connector on the driver side of the front motor assembly. Press the connector lock tab and carefully disconnect the harness. Verify connector pins are not corroded or damaged. Secure harness out of work area.
3. 3

   Remove inlet coolant hose
   Using hose clamp pliers, compress and slide the constant tension clamp back on the inlet hose (larger diameter hose from coolant reservoir). Twist hose gently to break seal, then pull straight off pump inlet nipple. Allow residual coolant to drain into pan. Inspect hose for cracks or deterioration.
4. 4

   Remove outlet coolant hose
   Compress and slide back the clamp on the outlet hose (smaller diameter hose to motor heat exchanger). Remove hose from pump outlet nipple using same twisting and pulling technique. Cap or plug hose ends to prevent contamination.
5. 5

   Remove coolant pump mounting bolts
   Remove the three mounting bolts securing the coolant pump to the front drive unit housing. Support pump with one hand while removing final bolt to prevent dropping. Note bolt locations as they may be different lengths.
6. 6

   Remove coolant pump assembly
   Carefully maneuver the coolant pump out of its mounting location, rotating as needed to clear surrounding components. The pump bracket may need to be tilted to clear the motor housing. Remove and discard the O-ring seal from the pump mounting surface.
7. 7

   Clean mounting surfaces
   Thoroughly clean the pump mounting surface on the drive unit housing using a lint-free cloth. Remove all traces of old O-ring material and coolant residue. Inspect mounting surface for cracks or damage. Ensure mating surface is completely clean and dry.
8. 8

   Install new O-ring seal
   Lightly lubricate the new O-ring seal with fresh EV coolant. Position O-ring in groove on new coolant pump, ensuring it seats properly without twisting. Verify O-ring is correct size and part number for this application.
9. 9

   Install new coolant pump
   Carefully position new coolant pump assembly into mounting location, aligning mounting holes with drive unit housing. Start all three mounting bolts by hand to ensure proper alignment before tightening. Tighten mounting bolts in star pattern to ensure even seating. Record torque values as no factory specifications are currently available in database.
10. 10

    Reconnect coolant hoses
    Install outlet hose onto pump outlet nipple, pushing firmly until fully seated. Install new constant tension clamp and position over hose barb. Repeat process for inlet hose. Ensure both hoses are fully seated with no gaps visible between hose and nipple.
11. 11

    Reconnect electrical connector
    Reconnect coolant pump electrical connector, ensuring it clicks firmly into place. Verify connector lock tab engages properly. Gently tug on connector to confirm secure connection.
12. 12

    Refill coolant system
    Close coolant drain valve. Using coolant refill funnel kit attached to coolant reservoir, slowly add fresh EV Battery/Motor Coolant. Fill reservoir to MAX line. Allow coolant to settle for 5 minutes, then add more as needed to maintain MAX level. Total system capacity is 10 quarts.
13. 13

    Bleed coolant system
    Reconnect 12V auxiliary battery. Reinstall high voltage service disconnect plug. Using factory-compatible OBD-II scan tool, access thermal management system menu. Command coolant pump to run at 50% speed for 2 minutes to circulate coolant and purge air. Monitor coolant level and add as needed. Repeat cycle three times, checking for leaks around pump after each cycle.
14. 14

    Final leak inspection
    With coolant pump running via scan tool, carefully inspect all hose connections and pump mounting area for leaks. Check coolant level and top off to MAX line if needed. Command pump to 100% speed for 30 seconds and recheck all connections. Ensure no coolant drips are present.

Reassembly

1. Reinstall front undertray panels and secure all fasteners
2. Remove vehicle from jack stands and lower to ground
3. Verify coolant level is at MAX line on reservoir with vehicle level
4. Clear any diagnostic trouble codes using scan tool
5. Verify high voltage system reconnection is secure and properly seated

Verification

• Start vehicle and allow thermal management system to initialize
• Verify no warning lights or coolant-related fault codes are present
• Using scan tool, monitor coolant pump operation and verify current draw is within normal range (typically 2-8 amps depending on speed)
• Check coolant temperature sensor readings are updating normally
• Take short test drive and monitor battery and motor temperatures remain in normal operating range
• After test drive, recheck coolant level and inspect pump area for any signs of leaks
• Verify coolant system maintains proper pressure using coolant pressure tester if available
• Document coolant pump serial number and installation date for service records

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