Radiator Removal and Service

This procedure covers the removal and service of the radiator (cooling system heat exchanger) on the 2025 Rivian EDV 500 dual motor AWD electric delivery van, including coolant drainage, component disconnection, and radiator replacement.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Radiator mounting bushings/grommets × 4 — Use OEM specification
• Coolant hose clamps × 4 — Replace if corroded
• Lower radiator drain plug O-ring × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle has been off and cooling for minimum 2 hours
3. Open hood and secure in fully open position
4. Disconnect 12V battery negative terminal and wait 5 minutes
5. Place coolant drain pan underneath vehicle front center section
6. Remove engine compartment undershield or front splash shield if equipped
7. Document routing of coolant hoses and electrical connections with photos for reference during reassembly

Procedure

1. 1

   Drain cooling system
   Locate the radiator drain petcock or drain plug at the lower driver side of the radiator. Slowly open the drain valve and allow coolant to drain completely into the drain pan. If equipped with a drain plug, remove it carefully. Expect approximately 10 quarts of coolant to drain. Once drained, close or reinstall the drain valve with new O-ring.
2. 2

   Remove upper radiator cover and seals
   Remove the plastic radiator cover panel by releasing the retaining clips along the top edge. Use panel removal tools to avoid breaking clips. Remove the rubber seal strip that spans the top of the radiator support. Set aside all trim pieces in organized manner for reinstallation.
3. 3

   Disconnect cooling fan electrical connectors
   Locate the electric cooling fan motor connectors on each side of the radiator assembly. Press the locking tabs and disconnect both fan motor electrical connectors. On EDV 500 models, there are typically two fan motors. Secure connectors away from work area to prevent damage.
4. 4

   Remove upper coolant hose
   Using hose clamp pliers, compress and slide the spring clamp away from the radiator connection point on the upper coolant hose. Gently twist the hose while pulling to break the seal and remove from the radiator inlet. Inspect hose for cracks or deterioration. Plug the open radiator connection with clean shop towels to prevent debris entry.
   ⚠Some residual coolant will drain from the upper hose. Have shop towels ready to catch spillage.
5. 5

   Remove lower coolant hose
   Access the lower radiator hose connection at the bottom of the radiator outlet. Compress the hose clamp and slide away from connection point. Twist and pull the lower hose from the radiator. Additional coolant will drain, ensure drain pan is positioned correctly. Plug the radiator outlet with clean towels.
6. 6

   Disconnect auxiliary coolant lines
   The EDV 500 has auxiliary coolant lines for battery thermal management that may connect to the radiator assembly. Identify these smaller diameter lines, typically using quick-connect fittings. Press the release tabs and disconnect all auxiliary coolant lines. Cap open lines immediately to prevent contamination and additional fluid loss.
   ℹ️Some auxiliary lines may be under slight residual pressure. Point connections away from yourself when disconnecting.
7. 7

   Disconnect transmission or power electronics cooler lines
   If equipped with integrated transmission or power electronics cooler lines running to the radiator, disconnect these lines at their radiator connection points. These are typically metal lines with threaded fittings or quick-connects. Use appropriate wrenches to avoid rounding fittings. Cap all open lines to prevent contamination.
8. 8

   Remove radiator mounting hardware
   Locate the radiator mounting bolts or brackets, typically at the upper corners and possibly lower corners of the radiator assembly. Remove all mounting bolts using appropriate socket or Torx bits. On Rivian EDV models, expect 4-6 mounting points. Keep hardware organized for reinstallation. Note the position of any rubber isolation bushings or brackets.
9. 9

   Remove radiator and fan assembly
   With all connections and mounting hardware removed, carefully lift the radiator and attached cooling fan assembly upward and out of the vehicle. The assembly may be heavy (30-40 lbs). Tilt slightly as needed to clear the radiator support brackets and condenser. Avoid damaging the AC condenser fins located directly behind the radiator. Set radiator on clean protected work surface.
   ⚠The radiator fins are delicate and easily damaged. Handle carefully and avoid contact with AC condenser fins.
10. 10

    Inspect and service radiator
    Inspect the removed radiator for physical damage, leaks, corrosion, or debris blockage. Check cooling fins for damage or excessive bending. If servicing rather than replacing, flush the radiator thoroughly with water and compressed air. Inspect and replace all rubber mounting bushings and grommets. Test radiator for leaks using pressure tester if available. If replacing radiator, transfer cooling fans to new radiator assembly if they are separate components.
11. 11

    Clean radiator mounting area
    With radiator removed, clean the radiator support area, removing any debris, leaves, or insects. Inspect the AC condenser for damage or debris. Use compressed air or shop vacuum to clean cooling fins on condenser. Check radiator support brackets for damage or corrosion. Inspect all coolant hose connections for cracks or deterioration.

Reassembly

1. Install new rubber mounting bushings/grommets in radiator brackets before installation
2. Carefully lower radiator and fan assembly into position, ensuring proper alignment with mounting brackets
3. Install and torque all radiator mounting bolts to manufacturer specifications (note: specific torque values not available in database)
4. Reconnect all transmission or power electronics cooler lines, ensuring proper thread engagement
5. Reconnect all auxiliary coolant lines, verifying positive engagement of quick-connect fittings
6. Install lower coolant hose with new clamp, positioning clamp away from hose end
7. Install upper coolant hose with new clamp in proper orientation
8. Reconnect both cooling fan motor electrical connectors until they click into place
9. Reinstall radiator upper seal strip and cover panel with all retaining clips fully seated
10. Reinstall front undershield or splash shield
11. Close radiator drain valve or install drain plug with new O-ring

Verification

• Fill cooling system with 10 quarts of specified EV Battery/Motor Coolant through the fill point, allowing time for air to escape
• Reconnect 12V battery negative terminal
• Start vehicle and allow cooling system to circulate. Monitor coolant level and add as needed to reach proper level
• Run vehicle through several heating and cooling cycles while monitoring for leaks at all connection points
• Check for proper cooling fan operation by observing fans activate during normal operation
• Verify coolant temperature remains within normal operating range on vehicle display
• Inspect all connection points for coolant seepage after test drive
• Check and top off coolant level after vehicle has cooled completely
• Clear any diagnostic trouble codes if warning lights appeared during service
• Verify no coolant puddles under vehicle after overnight parking

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