This procedure covers the replacement of the AC low pressure switch on a 2022 Rivian EDV 500 electric delivery van, requiring access to the AC system components and proper refrigerant recovery.

Warnings

Tools required

Parts

• AC low pressure switch × 1 — Use OEM Rivian specification
• O-ring kit for AC system × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As needed per system capacity

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure AC system has been off for at least 30 minutes to reduce pressure
3. Disconnect 12V battery negative terminal using appropriate battery disconnect procedure for electric vehicles
4. Verify high voltage system is in service mode and displays appropriate warnings on dash
5. Document current AC system pressures if system is operational
6. Locate AC low pressure switch on the low pressure line near the AC evaporator (driver side of vehicle under hood area)
7. Take photos of electrical connector routing and position for reference during reassembly

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to service ports on the AC system. Follow recovery machine manufacturer procedures to completely evacuate all R-1234yf refrigerant from the system. Record the amount of refrigerant recovered for recharge reference. Ensure recovery is complete before proceeding with any AC system disassembly.
2. 2

   Remove front underbody panels
   Remove the front underbody access panels to gain access to the AC lines and low pressure switch location. These panels are secured with plastic clips and fasteners. Use trim removal tools to avoid breaking clips. Set panels aside in a clean area.
3. 3

   Access AC low pressure switch
   Locate the AC low pressure switch on the low pressure line running from the compressor to the evaporator. It is typically mounted on the larger diameter line near the firewall on the driver side. Clean the area around the switch to prevent contamination from entering the AC system.
4. 4

   Disconnect electrical connector
   Press the locking tab on the electrical connector and carefully disconnect it from the AC low pressure switch. Inspect the connector terminals for corrosion or damage. If corrosion is present, clean with electrical contact cleaner.
5. 5

   Test old switch
   Using a digital multimeter, test the resistance across the switch terminals to verify switch failure. Compare readings to Rivian service specifications. Document findings for warranty or diagnostic records.
6. 6

   Remove AC low pressure switch
   Using an appropriate wrench, carefully unscrew the AC low pressure switch from the low pressure line. Turn counterclockwise to remove. Be prepared for residual refrigerant oil to drip from the port. Keep a clean rag ready to catch any oil and prevent contamination.
7. 7

   Inspect and clean mounting port
   Inspect the threaded port on the AC line for damage, cross-threading, or debris. Clean the threads with a wire brush if necessary. Check that the O-ring sealing surface is smooth and free from scratches or damage that could cause leaks.
8. 8

   Prepare new AC low pressure switch
   Remove the new AC low pressure switch from packaging. Verify part number matches Rivian specifications for 2022 EDV 500. Inspect the O-ring on the new switch and replace with new O-ring from kit if original appears damaged or dried out. Lightly lubricate the O-ring with clean refrigerant oil.
9. 9

   Install new AC low pressure switch
   Thread the new AC low pressure switch into the port by hand, turning clockwise. Ensure it threads smoothly without cross-threading. Once hand-tight, use a torque wrench to tighten to manufacturer specification. Since no torque specification is provided in database, tighten to snug specification plus 1/4 turn, being careful not to over-tighten and damage the port or switch.
10. 10

    Reconnect electrical connector
    Reconnect the electrical connector to the new AC low pressure switch. Ensure the locking tab clicks into place securely. Gently tug on the connector to verify it is properly seated and locked.
11. 11

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate the system to 500 microns or lower for at least 45 minutes. Monitor vacuum gauge to ensure system holds vacuum, indicating no leaks are present. If system does not hold vacuum, locate and repair leak before proceeding.
12. 12

    Recharge AC system
    Using AC recovery/recharge machine, charge the system with the proper amount of R-1234yf refrigerant as specified by Rivian for the EDV 500 (refer to underhood label for exact capacity). Add refrigerant slowly and monitor pressures. Include proper amount of PAG oil if significant oil was lost during service.
13. 13

    Perform leak test
    Using electronic refrigerant leak detector, carefully check all connections including the new low pressure switch for any refrigerant leaks. Pay special attention to the switch threads and O-ring seal. Pass the detector probe slowly around all fittings and connections.
14. 14

    Reinstall underbody panels
    Reinstall all front underbody access panels removed earlier. Ensure all clips and fasteners are properly seated. Verify no tools or parts were left in the work area.

Reassembly

1. Reconnect 12V battery negative terminal
2. Clear any service mode warnings from vehicle computer system
3. Verify all AC system pressures are within normal operating range
4. Route all wiring harnesses as shown in reference photos taken during disassembly
5. Ensure no interference between AC lines and any vehicle components or wiring

Verification

• Start vehicle and turn AC system to maximum cooling with fan on high
• Allow AC system to run for 10 minutes and verify cold air output from all vents
• Monitor AC system pressures with manifold gauges - low side should be 25-45 PSI and high side 200-300 PSI at ambient temperature (pressure varies with temperature)
• Verify AC low pressure switch cycles compressor on and off properly when system pressure drops below threshold
• Use multimeter to verify switch continuity changes state appropriately with pressure changes
• Perform final leak test around the new switch with electronic leak detector
• Check for any warning lights or fault codes related to AC system operation
• Test drive vehicle to verify AC performance under various conditions

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