Heat Pump System

Complete removal and replacement of the heat pump system assembly, including refrigerant recovery, component disconnection, and system recharge for the 2022 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• Heat pump compressor assembly × 1 — Use OEM specification
• Refrigerant line O-rings × 1 — Use OEM R-1234yf compatible seals
• Heat pump coolant hose clamps × 4 — Use OEM specification
• High voltage connector seals × 2 — Use OEM specification
• R-1234yf refrigerant × 1 — Per system capacity specification
• PAG oil for heat pump compressor × 1 — Use OEM EV-compatible PAG oil

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level ground and apply parking brake. Ensure vehicle is in Park mode.
2. Power off the vehicle completely using the main power button.
3. Disconnect the 12V auxiliary battery located in the front compartment.
4. Access the high voltage service disconnect using Rivian diagnostic tool to place system in service mode.
5. Remove the manual high voltage disconnect plug located beneath the rear floor access panel.
6. Verify high voltage de-energization using properly rated digital multimeter at the heat pump compressor power terminals (should read 0V).
7. Place high voltage lockout/tagout tags on the manual disconnect and document the lockout.
8. Raise and safely support the vehicle on jack stands to access underbody components.
9. Remove the underbody protective panels to access the heat pump assembly located in the right rear underbody area.
10. Connect the R-1234yf refrigerant recovery machine to the heat pump service ports.
11. Recover all refrigerant from the system according to EPA regulations and record the amount recovered.

Procedure

1. 1

   Drain coolant from heat pump circuit
   Place drain pan beneath heat pump coolant connections. Using the diagnostic tool, open the coolant isolation valves to drain mode. Loosen the coolant hose clamps at the heat pump inlet and outlet connections. Carefully disconnect coolant hoses and allow coolant to drain into pan. Seal hose ends with plugs to prevent contamination.
2. 2

   Disconnect high voltage power supply
   Wearing high voltage insulated gloves, remove the protective orange cover from the heat pump compressor power connector. Depress the locking tab and carefully disconnect the high voltage power connector from the compressor. Secure the connector away from work area with the protective cover reinstalled.
3. 3

   Disconnect refrigerant lines
   Using refrigerant line disconnect tools, carefully disconnect the suction and discharge refrigerant lines from the heat pump compressor. Be prepared for residual refrigerant release. Immediately cap all open refrigerant ports with protective caps to prevent moisture and contamination entry. Remove and discard all O-rings from the connection points.
4. 4

   Disconnect low voltage control harness
   Locate the low voltage control harness connector on the heat pump control module. Depress the connector locking tab and disconnect the harness. Note the connector orientation and any alignment features for reassembly.
5. 5

   Disconnect pressure and temperature sensors
   Disconnect the electrical connectors from the refrigerant pressure sensors and temperature sensors mounted on the heat pump assembly. Label each connector with tape to ensure correct reconnection during reassembly.
6. 6

   Remove heat pump mounting fasteners
   Locate and remove all mounting bolts securing the heat pump assembly to the vehicle chassis. There are typically four main mounting points. Support the heat pump assembly weight with a transmission jack or suitable support before removing the final fasteners.
7. 7

   Remove heat pump assembly
   With all connections disconnected and mounting fasteners removed, carefully lower the heat pump assembly from the vehicle. Maneuver the assembly past any obstructions, taking care not to damage surrounding components or wiring. Place the removed assembly on a clean work surface.
8. 8

   Prepare new heat pump assembly
   Remove protective caps from the new heat pump assembly. Verify that the new unit matches the removed unit in all mounting points and connection locations. Install new O-rings on all refrigerant line connections, lubricating them with clean PAG oil specific to R-1234yf systems. Verify that the compressor contains the correct amount of PAG oil per manufacturer specifications.
9. 9

   Install new heat pump assembly
   Using the transmission jack or support, carefully raise the new heat pump assembly into position in the vehicle. Align all mounting points with chassis brackets. Start all mounting bolts by hand to ensure proper alignment before tightening. Tighten mounting bolts in a cross-pattern to ensure even clamping force.
10. 10

    Reconnect refrigerant lines
    Remove protective caps from refrigerant ports on the new heat pump. Inspect the new O-rings for proper seating. Connect the suction and discharge refrigerant lines to the heat pump compressor, ensuring proper engagement of the quick-connect fittings. Verify that each connection is fully seated and locked.
11. 11

    Reconnect electrical connections
    Reconnect all pressure and temperature sensor connectors, ensuring proper locking engagement. Reconnect the low voltage control harness to the heat pump control module. Wearing high voltage insulated gloves, remove the protective cover from the high voltage power connector, align and connect it to the compressor, and verify the locking mechanism is fully engaged. Reinstall the orange protective cover.
12. 12

    Reconnect coolant lines
    Install new coolant hose clamps on the coolant hoses. Connect the coolant inlet and outlet hoses to the heat pump assembly, ensuring proper alignment and full insertion onto the fittings. Position and tighten the hose clamps securely. Using the diagnostic tool, close the coolant isolation valves to operational mode.
13. 13

    Refill coolant system
    Fill the coolant system with the specified EV Battery/Motor Coolant through the reservoir. Add approximately 2 quarts or until system is full. Use the diagnostic tool to run the coolant pump in purge mode to remove air from the heat pump circuit. Add additional coolant as needed to maintain proper level.
14. 14

    Evacuate and recharge refrigerant system
    Connect the R-1234yf service machine to the heat pump service ports. Evacuate the refrigerant system to a deep vacuum (minimum 500 microns) and hold for 30 minutes to verify system integrity and absence of leaks. If vacuum holds, charge the system with the specified amount of R-1234yf refrigerant according to the vehicle underhood label specifications.
15. 15

    System initialization and testing
    Reinstall the underbody protective panels. Lower the vehicle from jack stands. Reinstall the manual high voltage disconnect plug. Remove lockout/tagout tags. Reconnect the 12V auxiliary battery. Using the Rivian diagnostic tool, clear service mode and perform the heat pump system initialization procedure. Run the heat pump system self-test and verify all parameters are within specification. Check for refrigerant leaks using the leak detector at all connection points.

Reassembly

1. Ensure all underbody panels are securely reinstalled with all fasteners properly seated.
2. Verify all electrical connectors have positive locking engagement and weather seals are properly positioned.
3. Confirm coolant level is correct and system has been properly purged of air.
4. Document the amount of refrigerant added to the system for service records.

Verification

• Using the diagnostic tool, verify that no fault codes are present in the heat pump system.
• Verify that the heat pump compressor engages and operates smoothly when cabin heating or cooling is commanded.
• Check that cabin temperature control responds appropriately to temperature adjustments.
• Monitor coolant temperature to ensure proper circulation through the heat pump circuit.
• Perform a final refrigerant leak check at all service points using the leak detector.
• Verify that high voltage system status shows normal operation with no isolation faults.
• Test drive the vehicle and confirm proper HVAC operation in both heating and cooling modes.
• Check that battery thermal management system operates correctly and maintains target temperature range.

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