This procedure covers the removal and replacement of the AC compressor on a 2022 Rivian EDV 500 electric delivery van, including refrigerant recovery, compressor replacement, and system recharge.

Warnings

Tools required

Parts

• AC compressor assembly × 1 — Use OEM Rivian specification
• AC line O-ring kit × 1 — Use OEM specification for R-1234yf systems
• PAG 46 refrigerant oil × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As needed to refill system

Preparation

1. Park vehicle on level surface and engage parking brake
2. Put on high voltage safety gloves and follow Rivian high voltage lockout/tagout procedure
3. Access high voltage disconnect located behind driver's seat panel
4. Disconnect high voltage battery using service disconnect
5. Wait 5 minutes for capacitors to discharge
6. Use multimeter to verify zero voltage at motor power cables
7. Place high voltage warning tags on steering wheel and service disconnect
8. Disconnect 12V negative battery terminal
9. Raise vehicle on lift to access underbody components
10. Locate AC compressor mounted on front motor housing driver's side
11. Connect R-1234yf recovery machine to service ports

Procedure

1. 1

   Recover refrigerant from AC system
   Connect recovery machine to low and high side service ports. Follow machine manufacturer instructions to fully recover all refrigerant from the system. Record the amount of refrigerant recovered and the amount of oil extracted. This information is critical for proper refill quantities. Ensure recovery is complete before disconnecting lines.
2. 2

   Remove front undertray panels
   Remove the plastic undertray panels below the front motor assembly to access the AC compressor. Remove the fasteners securing the panels and set aside. The compressor is mounted on the driver's side of the front motor housing.
3. 3

   Disconnect AC compressor electrical connector
   Locate the high voltage electrical connector on the AC compressor. Press the release tab and carefully disconnect the connector. Verify again with multimeter that no voltage is present at the connector pins. Secure the connector away from work area.
4. 4

   Disconnect AC refrigerant lines
   Using appropriate AC line disconnect tools, remove the refrigerant lines from the compressor. There are two connections: suction line (larger) and discharge line (smaller). Immediately cap all open ports to prevent moisture and contamination from entering the system. Remove and discard old O-rings from line fittings.
   ⚠Small amounts of residual refrigerant may be present. Wear safety glasses and ensure ventilation.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Measure and record oil quantity
   Drain the oil from the old compressor into a clean measuring container through the suction port. Rotate the compressor clutch/shaft by hand several times to expel all oil. Record the exact quantity removed. This amount must be replaced in the new compressor plus any oil lost during recovery.
6. 6

   Remove compressor mounting bolts
   Locate the three mounting bolts securing the AC compressor to the front motor housing bracket. Using a socket wrench, remove all mounting bolts. Support the compressor weight while removing the final bolt. Carefully extract the compressor from the mounting bracket.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
7. 7

   Prepare new AC compressor
   Remove the new compressor from packaging. Check the shipping oil quantity by draining into a measuring container. Add or remove PAG 46 oil to match the quantity recorded from the old compressor (typically 120-180ml total system capacity). Rotate the compressor shaft by hand 10 times to distribute oil internally. Install new O-rings on compressor ports and apply a thin film of refrigerant oil to O-rings.
8. 8

   Install new compressor to bracket
   Position the new AC compressor into the mounting bracket on the front motor housing. Align all mounting holes. Install the three mounting bolts hand-tight first, then torque in a star pattern to specification. Ensure compressor is seated flush against bracket.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
9. 9

   Connect AC refrigerant lines
   Install new O-rings on both AC line fittings if not already done. Apply thin film of PAG 46 oil to O-rings. Connect the suction line (larger) and discharge line (smaller) to the compressor ports. Thread fittings by hand first to ensure proper alignment, then torque to specification using a torque wrench.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reconnect electrical connector
    Reconnect the high voltage electrical connector to the AC compressor. Ensure the connector clicks fully into place and the locking tab engages. Verify connection is secure by gently pulling on connector body.
11. 11

    Reinstall undertray panels
    Reinstall all undertray panels removed in step 2. Ensure all fasteners are properly secured and panels are seated correctly.
12. 12

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to 500 microns or below for at least 30 minutes. Monitor vacuum gauge - system should hold vacuum without rising, indicating no leaks. If vacuum does not hold, locate and repair leak before proceeding.
13. 13

    Recharge AC system
    Using R-1234yf recovery/recharge machine, recharge system with the amount of refrigerant recovered in step 1 (typically 1.3-1.5 lbs for EDV 500). Follow machine instructions for proper charging procedure. Add any additional refrigerant oil through service port if needed to match oil balance calculations.
14. 14

    Reconnect battery and high voltage system
    Reconnect 12V negative battery terminal. Remove lockout/tagout tags. Reconnect high voltage service disconnect behind driver's seat panel. Reinstall access panel. Remove high voltage safety gloves.

Reassembly

1. Verify all electrical connections are secure and properly seated
2. Confirm all AC line fittings are torqued to specification with no visible leaks
3. Ensure all undertray panels are reinstalled and secured
4. Remove all tools and equipment from vehicle and work area
5. Clear any diagnostic trouble codes from vehicle computer

Verification

• Start vehicle and allow HVAC system to initialize
• Set climate control to maximum cooling and fan speed
• Verify AC compressor engages - listen for compressor operation (quieter than ICE vehicles)
• Check that cold air is produced from vents within 2-3 minutes
• Monitor system pressures: low side should be 25-45 PSI, high side 200-300 PSI at ambient temperature
• Inspect all AC line connections for refrigerant leaks using UV dye detection if available
• Verify no AC-related diagnostic trouble codes are present
• Test AC performance at various temperature settings to ensure proper operation
• Check that compressor cycles on and off appropriately based on temperature demand

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