This procedure covers the removal and replacement of the AC evaporator core in a 2022 Rivian EDV 500, requiring dashboard removal and refrigerant system service.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM Rivian specification
• Evaporator case foam seals × 1 — Use OEM specification
• Cabin air filter × 1 — Use OEM specification
• AC system O-rings × 1 — Use OEM specification
• PAG oil for R-1234yf system × 1 — Rivian specified PAG oil
• Dashboard trim clips (assorted) × 1 — Replace as needed

Fluids

• R-1234yf refrigerant

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for airbag system discharge
3. Access high voltage service disconnect per manufacturer procedure and install lockout device
4. Verify HV system is de-energized with appropriate meter
5. Place fender covers and interior protection
6. Recover all R-1234yf refrigerant using certified recovery equipment and document amount recovered
7. Note refrigerant oil quantity removed for proper refill calculation
8. Allow vehicle interior to reach ambient temperature if previously running

Procedure

1. 1

   Remove lower dashboard panels and center console
   Remove lower driver and passenger knee bolsters using trim tools. Remove center console by removing storage tray, disconnecting USB connectors, and removing mounting fasteners. Label all electrical connectors with tape for reinstallation.
2. 2

   Disconnect steering column and remove instrument cluster
   Remove steering column lower shroud. Disconnect steering column electrical connectors including airbag clockspring connector. Remove instrument cluster bezel and cluster mounting fasteners. Carefully withdraw cluster and disconnect harnesses behind it.
3. 3

   Remove infotainment screen and upper dashboard
   Remove infotainment screen mounting fasteners (typically 4 Torx screws). Disconnect screen harness connectors. Remove upper dashboard trim panels working from center outward. Remove defrost vent grilles and upper dashboard mounting bolts.
4. 4

   Disconnect dashboard harness and HVAC controls
   Locate and disconnect main dashboard harness connectors at both A-pillars. Disconnect HVAC control module electrical connector. Disconnect blend door actuator and mode door actuator connectors from HVAC case. Tag each connector location.
5. 5

   Remove dashboard assembly
   With assistant support, remove remaining dashboard mounting bolts at both ends and center support. Carefully pull dashboard rearward to disengage from HVAC case and windshield area. Lift and remove dashboard assembly from vehicle. Store on padded surface.
6. 6

   Disconnect refrigerant lines at firewall
   From engine compartment, locate AC line connections at firewall leading to evaporator. Clean area around fittings thoroughly. Disconnect liquid line and suction line fittings using appropriate wrenches. Immediately cap all open fittings to prevent contamination. Remove any mounting brackets securing lines to firewall.
7. 7

   Remove HVAC case upper section
   Remove cabin air filter access door and filter. Remove mounting screws securing HVAC case upper half (typically 8-12 screws around perimeter). Carefully separate upper case half, noting location of any electrical connections to evaporator temperature sensor.
8. 8

   Remove evaporator core
   Disconnect evaporator temperature sensor from core. Note routing of thermal expansion valve and any capillary tubes. Carefully lift evaporator core from lower case half, taking care not to damage fins or bend refrigerant tubes. Inspect case for debris or moisture indicating previous leaks.
9. 9

   Prepare and install new evaporator
   Clean HVAC case interior with lint-free cloth. Inspect and replace foam seals on case mating surfaces. Add specified amount of PAG oil to new evaporator (typically 2-3 oz, verify with refrigerant recovery notes). Install new evaporator into lower case, ensuring proper seating and tube routing. Reconnect temperature sensor.
10. 10

    Reassemble HVAC case
    Install new cabin air filter. Align upper case half with lower, ensuring all seals are properly positioned. Install case mounting screws and tighten in cross pattern. Verify blend door and mode door operation is not restricted.
11. 11

    Connect refrigerant lines
    Install new O-rings on refrigerant line fittings, lubricating with PAG oil. From engine compartment, reconnect liquid and suction lines to evaporator tubes at firewall. Hand-tighten fittings first, then snug with wrenches. Do not overtighten aluminum fittings.
12. 12

    Reinstall dashboard assembly
    With assistant, position dashboard assembly into vehicle. Align with HVAC case and windshield cowl area. Install all dashboard mounting bolts and tighten securely. Reconnect all dashboard harness connectors, HVAC actuators, and control modules using reference photos.
13. 13

    Reinstall interior trim components
    Reinstall instrument cluster and connect harnesses. Reinstall steering column shrouds and reconnect column connectors. Install infotainment screen and connect harnesses. Reinstall all dashboard trim panels, bezels, and knee bolsters. Install center console and connect USB ports.
14. 14

    Evacuate and recharge AC system
    Connect R-1234yf service equipment to vehicle service ports. Evacuate system to 29 inches mercury vacuum for minimum 30 minutes. Monitor for vacuum decay indicating leaks. If vacuum holds, recharge system with original amount of refrigerant plus amount lost in evaporator. Add UV dye if desired for future leak detection.
15. 15

    Reconnect batteries and perform system checks
    Reconnect 12V battery negative terminal. Remove HV service disconnect lockout and reinstall HV disconnect per manufacturer procedure. Clear any fault codes using appropriate scan tool. Verify no airbag system faults. Initialize HVAC system and verify all actuators respond correctly.

Reassembly

1. Ensure all dashboard harness connectors are fully seated and locked
2. Verify all trim panels and clips are securely fastened with no rattles
3. Confirm steering column is properly secured and all functions operate normally
4. Check that infotainment screen boots properly and touchscreen responds
5. Verify all interior lighting functions correctly

Verification

• Start vehicle and verify no warning lights on instrument cluster
• Test HVAC system on all fan speeds and modes (defrost, floor, panel, bi-level)
• Verify cold air output from vents reaches expected temperature (typically 38-42°F at vents)
• Check for refrigerant leaks using electronic leak detector at all connection points
• Verify blend door and mode door operation through full range in climate control settings
• Test fresh air and recirculation modes
• Inspect engine compartment refrigerant line connections for proper torque and no leaks
• Confirm AC compressor engages and disengages properly when commanded
• Verify no unusual noises from HVAC system during operation
• Check that cabin air filter access door seals properly

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