This procedure covers removal and replacement of the EV radiator (thermal management cooling radiator) on the 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• EV thermal management radiator × 1 — Use OEM specification
• Radiator mounting grommets/isolators × 4 — Use OEM specification
• Coolant hose clamps × 4 — Spring clamps or worm gear clamps per OEM
• Coolant system O-rings × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow cooling system to cool completely for minimum 30 minutes
3. Disconnect 12V auxiliary battery using battery disconnect tool
4. Access HV battery service disconnect and follow manufacturer procedure to de-energize high voltage system
5. Verify HV system is de-energized using appropriate test equipment
6. Raise front of vehicle and secure on jack stands rated for vehicle weight
7. Remove front underbody panels to access radiator and cooling system components
8. Place coolant drain pan underneath radiator drain location

Procedure

1. 1

   Drain cooling system
   Locate coolant drain valve on lower radiator tank or remove lower radiator hose at radiator connection. Open drain valve or carefully release hose clamp and direct coolant flow into drain pan. Allow system to drain completely. Capture and properly dispose of old coolant according to local regulations.
2. 2

   Remove front fascia lower section
   Remove Torx screws securing lower front fascia section. Release plastic clips along upper edge using panel removal tools. Disconnect any electrical connectors for lighting or sensors integrated into fascia. Carefully pull fascia forward and set aside in protected area.
3. 3

   Disconnect cooling fan electrical connectors
   Locate electrical connectors for radiator cooling fan motors (typically two fans on EDV 500). Press release tabs and disconnect both fan motor connectors. If connector locks are present, squeeze or slide locks before disconnecting. Tag connectors for proper reassembly identification.
4. 4

   Remove cooling fans
   Remove mounting bolts securing cooling fan shroud assembly to radiator (typically four to six bolts around perimeter). Carefully lift fan assembly upward and away from radiator. Note orientation and position of any alignment pins or locating tabs. Set fan assembly aside in clean area.
5. 5

   Disconnect radiator hoses
   Using hose clamp pliers, release clamps on upper and lower radiator hoses at radiator connections. Twist hoses gently to break seal, then pull straight off radiator necks. If hoses use quick-connect fittings, press release tabs while pulling hose away. Plug hose ends with clean rags to prevent debris entry.
6. 6

   Disconnect auxiliary coolant lines
   Locate and disconnect auxiliary coolant lines running to battery thermal management system and motor cooling circuits. These may use quick-disconnect couplings or threaded fittings with O-rings. Note routing and connection points for each line. Cap all open fittings immediately to prevent contamination.
7. 7

   Remove upper radiator support brackets
   Remove bolts securing upper radiator mounting brackets to vehicle frame or core support. These brackets typically secure radiator top tanks and prevent forward movement. On EDV models, brackets may be integrated with charge port cooling ducting.
8. 8

   Remove radiator assembly
   Carefully lift radiator upward and forward out of lower mounting grommets. Tilt top of radiator toward engine bay while clearing lower radiator support. Guide radiator carefully past any remaining obstructions including AC condenser lines, wiring harnesses, or structural members. Remove radiator completely from vehicle.
9. 9

   Inspect and prepare mounting points
   Inspect lower radiator mounting grommets/isolators for damage, cracking, or compression. Replace all grommets as part of radiator replacement. Clean radiator mounting surfaces on frame/core support. Inspect AC condenser (if equipped) for damage from radiator removal. Check all coolant line fittings for corrosion or damage.
10. 10

    Install new radiator
    Install new mounting grommets into lower radiator support. Position new radiator above mounting location and carefully lower into place, guiding lower radiator tabs into grommets. Ensure radiator seats fully into all mounting points and sits level. Radiator should not be twisted or under stress when positioned.
11. 11

    Install upper mounting brackets
    Position upper radiator support brackets and install mounting bolts. Tighten bolts evenly to secure radiator without over-compressing mounting grommets. Verify radiator is properly aligned and has no contact with AC condenser or other components.
12. 12

    Reconnect coolant lines
    Install new O-rings on all threaded coolant line fittings where applicable. Reconnect upper and lower radiator hoses, ensuring hoses seat fully onto radiator necks. Install new hose clamps and position clamp bands over hose bead area. Connect auxiliary coolant lines to battery and motor cooling circuits, ensuring all quick-connect fittings click securely into place.
13. 13

    Install cooling fans
    Position cooling fan shroud assembly onto radiator, aligning mounting holes and any locating pins. Install fan shroud mounting bolts and tighten securely. Reconnect electrical connectors to both fan motors, ensuring connectors lock fully. Verify fan blades rotate freely without contacting shroud or radiator.
14. 14

    Fill and bleed cooling system
    Using coolant refill funnel if available, fill cooling system with fresh EV Battery/Motor Coolant to specified capacity (approximately 10 quarts total system capacity). Fill slowly to minimize air pockets. Locate cooling system bleed valves (typically on high points of system) and open to release trapped air. Close bleed valves when coolant flows without bubbles. Add coolant to reach proper fill level.

Reassembly

1. Reinstall front underbody panels and secure all fasteners
2. Reinstall lower front fascia section, ensuring all clips engage and electrical connectors are secured
3. Re-energize high voltage system following manufacturer procedures
4. Reconnect 12V auxiliary battery
5. Lower vehicle from jack stands

Verification

• Start vehicle and allow thermal management system to reach operating temperature while monitoring for leaks
• Verify both cooling fans activate when system calls for cooling
• Check coolant level after system reaches operating temperature and top off if necessary
• Use diagnostic scanner to verify no thermal management system fault codes are present
• Monitor battery and motor temperatures during test drive to confirm proper cooling system operation
• Perform final inspection under vehicle for any coolant leaks at radiator connections
• Verify all underbody panels and fascia components are properly secured

More procedures for this vehicle