AC Recharge

This procedure involves evacuating, leak testing, and recharging the AC refrigerant system on a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• R-1234yf refrigerant × 1 — Use OEM specification
• PAG 46 electric compressor oil (if needed) × 1 — Use Rivian OEM specification
• AC service port caps × 2 — Use OEM specification
• AC system O-rings (if service ports removed) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered off and key fob is at least 15 feet away from vehicle
3. Verify AC recovery/recharge machine is certified for R-1234yf and has been properly maintained
4. Check that refrigerant tank contains sufficient R-1234yf for complete system recharge
5. Connect diagnostic scan tool and verify no active HVAC system fault codes
6. Allow HVAC system to stabilize at ambient temperature (at least 30 minutes if recently operated)
7. Review vehicle service manual for specific refrigerant capacity (typically 1.8-2.2 lbs for EDV 500)
8. Ensure work area has adequate ventilation and no ignition sources nearby

Procedure

1. 1

   Locate and access AC service ports
   Open the front hood. Locate the low-pressure service port (larger diameter, typically on the suction line near the firewall) and high-pressure service port (smaller diameter, typically on the liquid line near the condenser). The EDV 500 service ports are accessible from the front compartment. Clean the area around both service ports to prevent contamination.
2. 2

   Connect recovery machine and recover refrigerant
   Remove caps from both service ports. Connect the AC recovery machine hoses to the low and high-pressure ports, ensuring proper connection to prevent leaks. Follow the machine manufacturer's instructions to recover all refrigerant from the system. The recovery process should take 10-15 minutes. Record the amount of refrigerant and oil recovered for reference. If significantly low refrigerant is recovered, note this for leak testing.
3. 3

   Perform initial leak inspection
   With the system empty, perform a visual inspection of all AC lines, connections, condenser, and evaporator housing for obvious signs of damage, corrosion, or oil residue that indicates a leak. Pay special attention to service port valves, compressor shaft seal area, and hose connections. Check the condenser front surface for road debris damage.
4. 4

   Vacuum test preparation
   Ensure all AC system components are properly secured and all connections are tight. Verify the recovery machine oil separator is functioning. Connect the vacuum pump to the manifold gauge set. Confirm both manifold valves are closed before proceeding to evacuation.
5. 5

   Evacuate AC system
   Open both low and high-side manifold valves. Start the vacuum pump and evacuate the system to at least 29.5 inches of mercury (500 microns preferred). Continue evacuation for a minimum of 45 minutes. This step removes air and moisture from the system, which is critical for proper AC performance and compressor longevity in the electric HVAC system.
6. 6

   Perform vacuum decay test
   After achieving deep vacuum (29.5+ inches Hg), close both manifold valves and shut off the vacuum pump. Monitor the gauge for 30 minutes. The vacuum should not rise more than 0.5 inches Hg. If vacuum rises significantly, there is a leak in the system. If leak is detected, pressurize system with nitrogen (max 150 psi) and use electronic leak detector to locate the source. Repair leak and repeat evacuation process.
7. 7

   Verify system oil level
   Based on the amount of oil recovered in Step 2, determine if oil replacement is needed. The Rivian electric AC compressor uses PAG 46 oil specifically formulated for electric compressors. If more than 2 oz of oil was lost, add the equivalent amount of fresh PAG 46 oil through the low-side port before recharging refrigerant. Use only Rivian-approved compressor oil to prevent electrical conductivity issues with the motor-driven compressor.
8. 8

   Charge refrigerant into system
   With the system still under vacuum, connect the refrigerant supply to the manifold gauge set center port. Place the refrigerant container on a scale to monitor quantity. Open the high-side valve first and allow liquid refrigerant to enter until pressure equalizes. Then open the low-side valve. Charge the system with the exact amount specified in the vehicle service manual (typically 1.9-2.1 lbs for EDV 500). For electric vehicles, precise refrigerant charge is critical as there is no engine heat to compensate for under/overcharge.
9. 9

   Verify initial pressures
   With the vehicle still off and system charged, observe static pressures on both high and low sides. At 70°F ambient temperature, static pressure should be approximately 70-85 psi on both sides. This confirms proper refrigerant charge quantity. Pressures will vary with ambient temperature but should be equal when system is not running.
10. 10

    Activate system and test operation
    Power on the vehicle to accessory or ready mode. Using the scan tool, command the HVAC system to maximum cooling with AC ON and fan at high speed. The electric compressor should activate within 10-15 seconds. Monitor both high and low-side pressures. Low side should drop to 25-35 psi and high side should rise to 175-225 psi at 70°F ambient. Compressor operation should be smooth and quiet without unusual vibration.
11. 11

    Measure vent temperatures
    Insert the thermometer probe into the center dashboard vent. With the system running at maximum cooling for 5-10 minutes, vent temperature should reach 38-45°F with ambient temperature around 70-75°F. Higher ambient temperatures will result in slightly warmer vent temps but temperature drop from ambient should be at least 35-40°F. This confirms proper system operation and charge level.
12. 12

    Perform electronic leak test
    While the system is running, use the electronic leak detector to check all connections, service ports, compressor seals, condenser, evaporator drain area, and all AC line fittings. Pay special attention to recently serviced connections. Any refrigerant leak will trigger the detector. If leaks are found, recover refrigerant, repair leak, and repeat evacuation and charging procedure.
13. 13

    Disconnect equipment and secure
    With the system verified operational, power off the vehicle. Close both manifold gauge valves and carefully disconnect the service hoses from both ports. Some residual refrigeant release is normal. Immediately install new service port caps and hand-tighten securely to prevent moisture entry and refrigerant loss. Store all equipment properly.
14. 14

    Clear diagnostic codes and document service
    Using the scan tool, clear any HVAC-related diagnostic trouble codes that may have been set during service. Verify no active fault codes remain. Document the service including refrigerant amount charged, oil added if any, static and running pressures, and vent temperatures. Update vehicle service records with date and refrigerant charge details.

Reassembly

1. Ensure both AC service port caps are installed and properly tightened
2. Verify all tools and equipment are removed from the engine compartment
3. Close and secure the front hood
4. Remove diagnostic scan tool and restore vehicle to normal operation

Verification

• Start the vehicle and turn AC to maximum cooling with recirculation mode ON
• Verify cold air is blowing from all dashboard vents within 60 seconds
• Center vent temperature should reach 38-45°F within 5-10 minutes at 70°F ambient
• Listen for smooth, quiet electric compressor operation with no unusual noises
• Check scan tool for any new HVAC fault codes - none should be present
• Verify no refrigerant smell inside or outside the vehicle
• Test system cycles properly when temperature is adjusted up and down
• Confirm defroster mode directs cooled air to windshield effectively
• Recheck service port areas for any signs of refrigerant leakage after 24 hours if possible

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