This procedure covers the removal and replacement of the radiator assembly on a 2025 Rivian EDV 500, including coolant system draining, component disconnection, and refilling of the EV battery/motor cooling system.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Replace if worn or cracked
• Lower radiator hose × 1 — Replace if worn or cracked
• Hose clamps × 4 — OEM spring clamps or equivalent
• EV Battery/Motor Coolant × 1 — Rivian-approved coolant only

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Ensure vehicle has been parked and powered off for at least 2 hours to allow cooling system to reach ambient temperature
2. Place vehicle on level ground and engage parking brake
3. Using a multi-meter, verify high-voltage system is fully de-energized per Rivian safety procedures
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system capacitors to discharge
5. Remove front fascia lower cover and front undertray to access radiator area
6. Position coolant drain pan beneath radiator drain location with minimum 12-quart capacity

Procedure

1. 1

   Drain cooling system
   Locate the radiator drain petcock at the lower driver side of the radiator. Slowly loosen the petcock by hand (plastic threads) and allow coolant to drain completely into the drain pan. Once drained, hand-tighten the petcock temporarily to prevent spillage during radiator removal.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Disconnect electrical connections
   Locate and disconnect the radiator fan electrical connector by pressing the release tab and pulling straight back. Disconnect the coolant temperature sensor connector on the radiator inlet tank. Label connections if necessary for reassembly reference.
3. 3

   Remove upper radiator hose
   Using hose clamp pliers, compress and reposition the upper radiator hose clamp away from the radiator inlet connection. Twist the hose gently to break the seal, then pull firmly to remove from the radiator. Be prepared for residual coolant spillage. Plug the hose opening with a clean shop towel.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
4. 4

   Remove lower radiator hose
   Repeat the hose removal process for the lower radiator hose at the outlet connection. Compress and reposition the hose clamp, twist to break seal, and remove hose. Allow any remaining coolant to drain into the pan. Plug the hose opening.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
5. 5

   Disconnect auxiliary cooler lines (if equipped)
   If equipped with transmission cooler lines running to the radiator, use a 19mm flare nut wrench to carefully loosen and disconnect the cooler line fittings from the radiator side tank. Cap open lines immediately to prevent contamination. Be prepared for minor fluid spillage.
   Torque spec

   Transmission Cooler Lines25 Nm (18 lb-ft)
6. 6

   Remove radiator mounting bolts
   Locate the four radiator mounting bolts (two upper, two lower) securing the radiator to the support brackets. Using a 10mm socket, remove all four mounting bolts. Note that these mount to plastic brackets - do not force or pry. Keep bolts organized for reinstallation.
   ⚠Mounting brackets are plastic composite. Apply steady pressure only - do not impact or over-torque.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
7. 7

   Remove radiator assembly
   Carefully lift the radiator assembly straight up and out of the vehicle. The radiator will separate from lower locating pins. Tilt slightly forward at the top to clear any remaining connections. Inspect the condenser (if equipped) behind the radiator for damage during removal. Set radiator on a clean, protected work surface.
8. 8

   Inspect and prepare new radiator
   Inspect mounting bracket condition and lower locating pins for damage. Clean mounting surfaces with a lint-free cloth. Transfer any reusable components from old radiator to new unit (temperature sensor if separate, fan shroud brackets if needed). Ensure drain petcock is closed on new radiator.
9. 9

   Install new radiator assembly
   Carefully lower the new radiator into position, aligning lower locating pins with the rubber grommets in the lower support. Ensure radiator seats fully and is flush with all mounting points. Verify fan shroud alignment and clearance before securing.
10. 10

    Install radiator mounting bolts
    Install all four radiator mounting bolts finger-tight first to ensure proper alignment. Using a torque wrench and 10mm socket, tighten bolts to specification in a cross pattern (upper left, lower right, upper right, lower left). Do not exceed specified torque on plastic mount points.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect coolant hoses
    Remove plugs from coolant hoses. Inspect hose ends for damage and replace if worn. Install lower radiator hose first, pushing firmly onto outlet until fully seated. Position new hose clamp 10-15mm from hose end and secure to specification. Repeat for upper radiator hose. Ensure hoses are not kinked or twisted.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reconnect auxiliary lines and electrical
    If equipped, reconnect transmission cooler lines to radiator fittings and torque to specification using a flare nut wrench. Reconnect coolant temperature sensor connector and radiator fan electrical connector. Ensure all connections click securely into place.
    Torque spec

    Transmission Cooler Lines25 Nm (18 lb-ft)
13. 13

    Refill cooling system
    Using Rivian-approved EV Battery/Motor Coolant only, slowly fill the cooling system through the reservoir to the COLD MAX line. Allow time for coolant to settle and air to escape. Add coolant as needed. Install reservoir cap hand-tight. Do not overfill.
14. 14

    Bleed cooling system
    With the reservoir cap installed, power on the vehicle to accessory mode (do not drive). Activate the climate control to MAX heat and high fan. Allow the coolant pumps to circulate for 10 minutes while monitoring for leaks. Check coolant level and add if necessary. Repeat until coolant level stabilizes and no air bubbles are visible in the reservoir.
    ⚠Monitor coolant temperature during bleeding process. If overheating occurs, shut down immediately and investigate for air locks or leaks.

Reassembly

1. Reinstall front undertray and lower fascia cover, ensuring all clips are fully engaged
2. Reconnect 12V auxiliary battery negative terminal
3. Verify all connections are secure and no tools or parts remain in engine compartment
4. Wipe down any coolant spills to prevent slipping hazards and corrosion

Verification

• Start vehicle and allow cooling system to reach operating temperature while monitoring for leaks at all connection points
• Check coolant level in reservoir after system reaches operating temperature - should be at HOT MAX line
• Verify radiator fans activate when cooling is required
• Test drive vehicle and monitor battery/motor temperatures via vehicle display to ensure proper cooling system operation
• Recheck coolant level after test drive and top off if necessary
• Inspect for any coolant leaks or drips after 24 hours of normal operation
• Clear any diagnostic trouble codes related to high-voltage system disconnection using appropriate scan tool

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