AC Hose - High Side

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

Warnings

Tools required

Parts

• AC high-side hose assembly × 1 — Use OEM Rivian specification
• AC line O-ring kit × 1 — Use OEM Rivian specification
• AC system oil (POE oil for R-1234yf) × 1 — Use manufacturer-specified POE oil
• R-1234yf refrigerant × 1 — As required by system capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify work area has adequate ventilation for refrigerant work
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Access the HV battery disconnect using Rivian service procedures and disable high-voltage system
5. Allow AC system to equalize to ambient temperature if recently operated
6. Identify the high-side AC hose routing from compressor to condenser
7. Document refrigerant charge amount from underhood label for recharge reference
8. Prepare R-1234yf recovery machine according to manufacturer instructions

Procedure

1. 1

   Recover refrigerant from AC system
   Connect the R-1234yf recovery machine to the AC service ports (high and low side). Start the recovery process and allow the machine to fully evacuate all refrigerant from the system. Recovery is complete when system pressure reads 0 PSI or in vacuum and no additional refrigerant is being extracted. Record the amount of refrigerant and oil recovered for recharge calculations.
2. 2

   Access high-side hose connections
   Remove the front access panels or underbody shields as necessary to access the high-side AC hose. On the EDV 500, the high-side hose runs from the compressor (mounted near the front drive unit) to the condenser at the front of the vehicle. Remove any cable ties or retention clips securing the hose to the vehicle structure.
3. 3

   Disconnect high-side hose at compressor
   Using appropriate line wrenches to prevent damage, disconnect the high-side hose fitting at the compressor discharge port. Support the hose to prevent stress on connected components. Cap or plug the compressor port immediately to prevent moisture ingress and contamination. Inspect the O-rings and sealing surfaces for damage.
4. 4

   Disconnect high-side hose at condenser
   Locate the condenser connection point at the front of the vehicle. Use line wrenches to carefully disconnect the high-side hose from the condenser inlet. Cap the condenser port immediately. Note the routing and any mounting bracket positions for reinstallation reference.
5. 5

   Remove high-side hose assembly
   Remove any remaining mounting brackets or clips securing the hose along its routing path. Carefully extract the high-side hose from the vehicle, noting the exact routing path, clearances from high-voltage components, and any grommets or isolators used. Take photos if necessary for installation reference.
6. 6

   Inspect and prepare new hose
   Unpack the new high-side hose assembly and verify it matches the original part. Install new O-rings at all connection points, lubricating them with clean POE oil compatible with R-1234yf systems. Ensure O-rings are properly seated in their grooves. Check that protective caps are in place on all fittings.
7. 7

   Route and position new high-side hose
   Route the new high-side hose along the same path as the original, ensuring adequate clearance from high-voltage cables, drive unit components, and sharp edges. Install any grommets or isolators in their original positions. Verify the hose will not contact moving parts or heat sources.
8. 8

   Connect high-side hose to condenser
   Remove the protective cap from the condenser port and new hose fitting. Inspect sealing surfaces for cleanliness. Hand-thread the connection to prevent cross-threading, then tighten using line wrenches. Follow manufacturer torque specifications if available, or tighten to industry-standard specification for AC line fittings of this size.
9. 9

   Connect high-side hose to compressor
   Remove protective caps from the compressor discharge port and hose fitting. Verify O-ring is properly positioned and lubricated. Hand-thread the connection first, then tighten with line wrenches to proper specification. Ensure the hose alignment does not place stress on the compressor port.
10. 10

    Secure hose and reinstall mounting hardware
    Install all mounting brackets and clips in their original positions to secure the high-side hose. Use new cable ties as needed to prevent hose movement or vibration. Verify all clearances are maintained and the hose cannot contact other components during vehicle operation.
11. 11

    Evacuate AC system
    Connect the vacuum pump to the AC service ports. Evacuate the system to a minimum of 29 inches Hg (500 microns or better is preferred). Maintain vacuum for at least 30-45 minutes to remove all moisture and air from the system. If vacuum does not hold, there may be a leak that requires repair.
12. 12

    Leak test the system
    After successful evacuation, introduce a small amount of R-1234yf refrigerant (approximately 50 PSI) into the system. Use a refrigerant leak detector to check all connections, particularly the newly installed high-side hose fittings at both ends. If leaks are detected, recover refrigerant, repair leaks, and repeat evacuation process.
13. 13

    Recharge AC system
    Using the R-1234yf recharge machine, add the proper amount of refrigerant as specified on the vehicle underhood label. Add the appropriate amount of POE oil to compensate for oil lost during component replacement (typically 1-2 oz for hose replacement). Verify final system charge weight matches specification.
14. 14

    Reinstall access panels and reconnect battery
    Reinstall any underbody shields, access panels, or trim pieces removed during the procedure. Reconnect the high-voltage system following Rivian reconnection procedures. Reconnect the 12V battery negative terminal.

Reassembly

1. Ensure all AC line connections are tight and properly torqued
2. Verify all protective shields and panels are reinstalled to prevent damage to AC lines
3. Double-check that AC hose routing maintains clearance from high-voltage components and moving parts
4. Confirm all cable ties and mounting brackets are secure

Verification

• Start the vehicle and allow it to complete its power-up sequence
• Turn on the AC system to maximum cooling and high fan speed
• Verify compressor engages (listen for operation or check system data)
• Check that both high and low side pressures are within normal operating range using manifold gauges
• Verify cold air is being produced at the cabin vents with temperature drop of at least 40°F from ambient
• Perform final leak check of all connections with refrigerant detector while system is running
• Verify no unusual noises or vibrations from the AC system during operation
• Test AC system operation through several on/off cycles to ensure proper function
• Check for any refrigerant odor in cabin or under hood that might indicate a leak

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