This procedure covers the diagnosis and replacement of the AC pressure sensor on a 2022 Rivian EDV 500 dual motor AWD electric delivery van, including refrigerant recovery and recharge.

Warnings

Tools required

Parts

• AC pressure sensor × 1 — Use OEM Rivian specification
• Sensor O-ring seal × 1 — Use OEM Rivian specification
• R-1234yf refrigerant × 1 — As required per system capacity
• PAG oil for R-1234yf systems × 1 — As required per sensor replacement guidelines

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from cabin area
3. Place vehicle into service mode following Rivian service procedures
4. Disconnect 12V battery negative terminal and wait 2 minutes
5. Verify AC system pressure using manifold gauges to confirm system contains refrigerant
6. Connect AC recovery machine to service ports
7. Document pre-service AC system pressures and refrigerant quantity for reference
8. Ensure work area has proper ventilation for refrigerant handling

Procedure

1. 1

   Diagnose AC Pressure Sensor Fault
   Connect scan tool to vehicle diagnostic port. Navigate to HVAC system and read current fault codes. Monitor live data for AC pressure sensor readings. Compare sensor voltage output to service specifications (typically 0.5-4.5V range). Check for sensor signal circuit short to ground, short to power, or open circuit conditions. Verify fault is sensor-related and not wiring harness issue.
2. 2

   Recover AC Refrigerant
   Connect approved R-1234yf recovery machine to high and low side service ports. Follow machine manufacturer instructions to recover all refrigerant from the system. Record the amount of refrigerant recovered and amount of oil captured. Allow recovery process to run until machine indicates completion and system vacuum stabilizes. Close service port valves and disconnect recovery machine hoses.
3. 3

   Access AC Pressure Sensor
   The AC pressure sensor is typically located on the high-pressure liquid line near the condenser assembly in the front compartment. Remove front lower splash shield fasteners and lower shield for access. If necessary, remove any electrical harness clips or brackets obstructing access to the sensor. The sensor will have a threaded body screwed into the AC line with an electrical connector.
4. 4

   Disconnect Sensor Electrical Connector
   Locate the electrical connector on the AC pressure sensor. Press the locking tab or release mechanism while pulling the connector straight off the sensor. Inspect connector terminals for corrosion, damage, or moisture intrusion. If connector shows damage, connector pigtail repair may be required before proceeding.
5. 5

   Remove Failed AC Pressure Sensor
   Using appropriate wrench or socket, carefully unthread the AC pressure sensor from the high-pressure line fitting. Turn counterclockwise to remove. Note the sensor orientation and installation depth. Remove and discard the old O-ring seal from the sensor port. Inspect the sensor port threads for damage or debris. Clean port threads with a lint-free cloth if necessary.
6. 6

   Prepare New AC Pressure Sensor
   Remove new AC pressure sensor from packaging and verify correct part number matches vehicle application. Install new O-ring seal onto sensor threads, ensuring it seats properly in the O-ring groove. Lightly lubricate O-ring with clean PAG oil compatible with R-1234yf refrigerant systems. Do not over-lubricate as excess oil will contaminate the AC system.
7. 7

   Install New AC Pressure Sensor
   Thread new AC pressure sensor into the high-pressure line port by hand, turning clockwise. Ensure sensor threads engage smoothly without cross-threading. Hand tighten until O-ring seats and sensor bottoms out. Using torque wrench and appropriate socket, tighten sensor to specification. Since no torque specification is provided in database, follow manufacturer instructions typically found on sensor packaging or tighten to snug specification plus 1/6 turn (approximately 60 degrees).
8. 8

   Reconnect Sensor Electrical Connector
   Align electrical connector with sensor terminals and push firmly until locking tab clicks into place. Gently tug on connector to verify it is fully seated and locked. Ensure connector seal is properly positioned to prevent moisture intrusion. Route any wire harness clips back to original positions.
9. 9

   Evacuate AC System
   Connect vacuum pump to AC service ports via manifold gauge set. Open high and low side valves and start vacuum pump. Evacuate system to 29.9 inches of mercury (500 microns or less). Maintain vacuum for minimum 30 minutes to remove all air and moisture from system. Close manifold valves and turn off vacuum pump. Monitor vacuum gauge for 10 minutes to verify system holds vacuum without decay, confirming no leaks.
10. 10

    Recharge AC System with Refrigerant
    Using R-1234yf charging machine, connect to service ports. Reference underhood AC specification label for correct refrigerant charge amount (typically between 1.5-2.5 lbs for commercial vans). Input correct charge amount into machine. Begin charging process following machine instructions. Charge refrigerant into low side with vehicle off. Add appropriate amount of fresh PAG oil to replace oil lost during recovery (typically 1-2 oz for sensor replacement).
11. 11

    Leak Test New Sensor Installation
    With system fully charged, use electronic leak detector or UV light (if UV dye present) to check for leaks around new AC pressure sensor installation point. Carefully probe around sensor threads and O-ring seal area. Check for any refrigerant escaping. If leak is detected, recover refrigerant, remove sensor, verify O-ring installation, and reinstall.
12. 12

    Verify Sensor Operation
    Reconnect 12V battery negative terminal. Exit service mode and power on vehicle. Connect scan tool and navigate to HVAC live data. Start vehicle AC system and monitor AC pressure sensor readings. High side pressure should read approximately 150-250 PSI at idle depending on ambient temperature. Low side should read 25-45 PSI. Verify sensor voltage changes appropriately with compressor cycling. Clear any diagnostic trouble codes.
13. 13

    Perform AC System Performance Test
    Set HVAC controls to maximum cooling, recirculation mode, and high blower speed. Allow system to run for 5-10 minutes. Verify compressor engages and cycles properly based on pressure sensor inputs. Measure vent temperature with thermometer; should achieve 38-45°F depending on ambient conditions. Monitor scan tool data to confirm pressure sensor readings remain stable and within normal operating range.

Reassembly

1. Reinstall front lower splash shield and secure all fasteners
2. Reinstall any trim panels or covers removed for access
3. Verify all electrical connections are secure and properly routed
4. Ensure no tools or parts are left in engine compartment

Verification

• Verify AC system cools effectively with vent temperatures below 45°F at maximum cooling setting
• Confirm no AC-related diagnostic trouble codes present in system
• Check AC pressure sensor live data shows appropriate high and low side pressures during operation
• Verify no refrigerant leaks detected at sensor installation point
• Confirm compressor clutch engages and disengages properly based on pressure sensor inputs
• Test AC operation through multiple on/off cycles to ensure consistent performance
• Verify proper refrigerant charge level matches service specification label

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