AC Compressor Oil Add

This procedure covers adding compressor oil to the AC system of a 2023 Rivian EDV 500 electric delivery van, typically performed after refrigerant loss or component replacement.

Warnings

Tools required

Parts

• PAG oil for electric vehicle AC compressor × 1 — Use Rivian-specified POE or PAG oil only
• AC service port caps × 2 — Use OEM specification
• O-rings for AC fittings × 4 — Use OEM specification

Fluids

• Electric vehicle AC compressor oil (POE or PAG as specified) — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify vehicle has been off for at least 10 minutes to allow HV system to deactivate
3. Connect Rivian diagnostic software and verify no active HV system faults
4. Disable HV system following Rivian service procedures and install safety lockout tags
5. Verify ambient temperature is between 60-90°F for accurate AC system work
6. Ensure AC recovery machine is certified for R-1234yf refrigerant
7. Verify AC compressor oil is correct specification for Rivian electric compressor (check service bulletin)
8. Document current AC system operation and any fault codes
9. Photograph AC system connections before disassembly

Procedure

1. 1

   Connect recovery equipment
   Connect R-1234yf recovery machine to both high and low side service ports. Ensure all connections are secure and manifold valves are in correct position for recovery mode. Remove service port caps and inspect port valves for debris or damage.
2. 2

   Recover existing refrigerant
   Start recovery machine and recover all refrigerant from the system. Monitor gauges until system pressure reaches vacuum. Continue recovery for at least 5 minutes after pressure stabilizes to ensure complete refrigerant removal. Record the amount of refrigerant recovered and oil captured by recovery machine.
3. 3

   Calculate required oil quantity
   Determine oil quantity needed based on service history: If replacing compressor, add full compressor oil charge (typically 4-6 oz for Rivian EDV 500). If servicing other components, add 1 oz for condenser replacement, 2 oz for evaporator replacement, or match amount lost if measured. Consult Rivian service information for exact specifications. Subtract any oil recovered by recovery machine from total needed.
4. 4

   Prepare oil injector
   Fill AC oil injector tool with the precisely measured amount of Rivian-specified compressor oil. Ensure oil is clean and free of contamination. Verify oil type matches requirement for electric compressor (typically POE oil for EV systems). Prime injector to remove air bubbles.
5. 5

   Inject compressor oil
   Connect oil injector to low side service port. Slowly inject measured oil into system using injector tool. For electric compressors, oil injection through low side ensures proper distribution. Take 2-3 minutes to inject oil slowly to allow it to distribute through system. Disconnect injector and immediately cap service port.
6. 6

   Perform vacuum procedure
   Connect vacuum pump to AC manifold gauge set. Open both high and low side valves and start vacuum pump. Pull system down to at least 500 microns. This typically takes 30-45 minutes for the Rivian EDV 500 system. Monitor vacuum gauge continuously.
7. 7

   Vacuum hold test
   After reaching 500 microns, close manifold valves and shut off vacuum pump. Monitor system vacuum for 15 minutes. Vacuum should hold steady with no more than 100 micron rise. If vacuum rises significantly, there is a leak or moisture present. Re-evacuate for additional 30 minutes if needed.
8. 8

   Charge refrigerant to specification
   Connect refrigerant tank to manifold gauge set through electronic scale. Rivian EDV 500 typically requires approximately 2.2 lbs (1000g) of R-1234yf - verify exact amount in service information. Charge liquid refrigerant through high side with engine off until 80% of charge is added, then complete charging through low side. Monitor weight on scale continuously.
9. 9

   Re-enable HV system
   Remove HV safety lockout tags. Using Rivian diagnostic software, perform HV system wake-up procedure. Verify all HV systems come online without faults. Confirm HVAC compressor is enabled and responsive to commands.
10. 10

    Initial AC system operation
    Start vehicle and set HVAC to maximum cooling, recirculation mode, high blower speed. Allow system to run for 5 minutes. Monitor AC pressures: low side should stabilize at 25-45 PSI, high side at 150-250 PSI depending on ambient temperature. Use diagnostic software to monitor compressor operation and current draw.
11. 11

    Check for leaks
    Using electronic leak detector, check all AC fittings, service ports, compressor connections, and condenser/evaporator areas for refrigerant leaks. Pay special attention to any connections that were disturbed. If UV dye is available, add per manufacturer instructions and check with UV light.
12. 12

    Verify system performance
    With system running at maximum cooling, measure vent temperature using thermometer. Vent temp should reach 38-45°F within 10 minutes at 70-80°F ambient. Check that compressor cycles properly and high voltage draw is within specifications (monitor with diagnostic software). Verify no abnormal noises from compressor.

Reassembly

1. Install new service port caps on both high and low side ports - hand tighten only
2. Secure all wiring harnesses and ensure no interference with moving parts
3. Remove all tools and equipment from vehicle
4. Clear any service mode flags using Rivian diagnostic software

Verification

• Perform final AC performance test: vent temperature should be 38-45°F at maximum cooling
• Verify using diagnostic software that AC compressor operation shows no faults and current draw is within normal range
• Confirm AC pressures are stable: low side 25-45 PSI, high side 150-250 PSI at idle (ambient dependent)
• Check that AC system cycles properly and maintains temperature control
• Verify no refrigerant leaks detected at any fittings or components
• Test AC operation in all HVAC modes (defrost, floor, vent) to ensure proper function
• Road test vehicle and verify AC cooling performance under load
• Document oil quantity added, refrigerant charge amount, and final system pressures in service records

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