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

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• R-1234yf refrigerant × 1 — Per vehicle specification label
• PAG oil for R-1234yf systems × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect 12V battery negative terminal and wait 5 minutes for system discharge
3. Verify AC system refrigerant type matches R-1234yf on underhood label
4. Raise and support vehicle on jack stands at manufacturer-approved lift points
5. Remove front wheels for improved access to condenser area
6. Remove front underbody panels and skid plates as needed for access
7. Document refrigerant charge amount during recovery for proper refill

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports following manufacturer instructions. Recover all refrigerant from the system and record the amount removed. This will guide proper recharge quantity. Ensure recovery is complete before proceeding with any line disconnection.
2. 2

   Remove front fascia and grille assembly
   Remove plastic trim clips and fasteners securing the front fascia. Disconnect any electrical connectors for sensors or lighting. Carefully pull fascia forward and remove from vehicle. Remove upper grille assembly to expose condenser mounting area. Store all fasteners organized by location for reassembly.
3. 3

   Disconnect AC lines from condenser
   Locate the AC line connections at the condenser inlet and outlet. Use appropriate wrench to loosen and remove AC line fittings. Cap all open connections immediately to prevent moisture and debris entry. Discard old O-rings from the fittings and lines.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Disconnect auxiliary components
   Disconnect any electrical connectors for condenser fan motors if equipped. Remove wiring harness clips or brackets attached to condenser. Note routing of all wiring and hoses for proper reinstallation. If transmission or battery cooler is mounted to condenser, carefully separate these components.
5. 5

   Remove condenser mounting hardware
   Locate all condenser mounting bolts, typically at top and bottom brackets. Remove the mounting bolts securing condenser to radiator support or chassis mounting points. Support condenser weight during bolt removal to prevent it from falling.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
6. 6

   Extract condenser from vehicle
   Carefully tilt and maneuver condenser out from between radiator and front support structure. Watch for any remaining brackets, clips, or rubber isolators that may still be attached. Inspect condenser mounting location for damage or debris and clean as needed.
7. 7

   Prepare new condenser for installation
   Remove shipping caps from new condenser. Drain and measure PAG oil from old condenser if possible. Add equivalent amount of fresh PAG oil specified for R-1234yf systems to new condenser following manufacturer specifications. Install new rubber isolators or mounting grommets on condenser if equipped.
8. 8

   Install new condenser
   Carefully position new condenser into mounting location, ensuring proper orientation with inlet/outlet ports accessible. Align condenser with all mounting holes and brackets. Install condenser mounting bolts finger-tight initially, then torque to specification in a cross-pattern to ensure even seating.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
9. 9

   Reconnect auxiliary components
   Reattach any transmission or battery cooler lines if previously disconnected. Reconnect electrical connectors to condenser fan motors. Secure all wiring harness clips and brackets, ensuring wires are routed away from sharp edges and moving components.
10. 10

    Connect AC lines with new O-rings
    Install new O-rings on all AC line fittings, lubricating with refrigerant oil. Connect AC lines to condenser inlet and outlet ports, ensuring proper alignment. Thread fittings by hand first to avoid cross-threading. Torque AC line fittings to specification using torque wrench.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Reinstall front fascia and grille
    Reinstall upper grille assembly and secure with original fasteners. Reconnect any electrical connectors for sensors and lighting. Position front fascia carefully, aligning all mounting points. Install all trim clips and fasteners, ensuring proper fit and finish.
12. 12

    Evacuate and recharge AC system
    Connect vacuum pump to AC system service ports. Evacuate system to at least 29 inches Hg vacuum and hold for minimum 30 minutes to verify no leaks and remove moisture. If vacuum holds, recharge system with recorded amount of R-1234yf refrigerant using refrigerant scale for accuracy. Add UV dye if desired for future leak detection.

Reassembly

1. Reinstall front wheels and torque lug nuts to specification
2. Reinstall all underbody panels and skid plates removed for access
3. Reconnect 12V battery negative terminal
4. Verify all electrical connections are secure and properly routed
5. Ensure no tools or parts are left in engine compartment

Verification

• Start vehicle and activate climate control to maximum cooling
• Verify condenser fan operates properly if equipped
• Check AC system performance - center vents should produce cold air within 2-3 minutes
• Inspect all AC line connections for signs of refrigerant leaks using leak detector or soap solution
• Monitor AC system pressures using gauge set to verify proper operation within specification
• Verify no warning lights or fault codes related to HVAC system
• Test drive vehicle and confirm consistent AC cooling performance under various conditions
• Perform final UV leak check if dye was added during recharge

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