This procedure covers the removal and replacement of the AC compressor on a 2023 Rivian EDV 500 electric delivery van, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC compressor assembly × 1 — Use OEM specification
• AC line O-ring kit × 1 — R-1234yf compatible O-rings
• PAG oil for electric compressor × 1 — POE oil for R-1234yf systems
• R-1234yf refrigerant × 1 — Per system capacity specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery and wait 5 minutes for system capacitors to discharge
3. Follow Rivian service procedures to de-energize high voltage system and install safety lockout
4. Verify HV system is de-energized using insulated multimeter at service disconnect location
5. Raise front of vehicle and secure on jack stands
6. Remove front underbody access panels to expose AC compressor area
7. Place drip pans beneath work area to catch any residual refrigerant oil

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to low and high side service ports. Follow machine instructions to fully recover all refrigerant from the system. Record the amount of oil recovered for later replacement. Once recovery is complete, close service valves and disconnect recovery machine.
2. 2

   Disconnect high voltage connector from compressor
   Locate the orange high voltage connector on the AC compressor. Verify again with multimeter that no voltage is present. Press the release tab and carefully disconnect the HV connector from the compressor. Secure connector away from work area with cable tie to prevent accidental contact.
   ⚠️Even with system locked out, treat all orange HV connectors as energized until verified safe with proper test equipment.
3. 3

   Disconnect clutch connector
   Remove the small electrical connector for the compressor clutch control. Remove the clutch connector bolt and set aside for reinstallation. Note connector orientation for reassembly.
   Torque spec

   Clutch Connector Bolt8 Nm (6 lb-ft)
4. 4

   Disconnect AC refrigerant lines
   Using appropriate line disconnect tools, separate the suction and discharge lines from the compressor. Immediately cap all open lines and compressor ports with clean AC line caps to prevent contamination and moisture entry. Inspect O-rings on lines and note their condition.
   ⚠Some residual refrigerant oil will drain from lines. Ensure drip pans are positioned to catch fluid.
5. 5

   Remove compressor mounting bolts
   Locate and remove all AC compressor mounting bolts securing the unit to its bracket. Support the compressor weight by hand while removing the final bolt. Carefully lower compressor from mounting position and remove from vehicle.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
6. 6

   Drain and measure oil from old compressor
   Drain all oil from the removed compressor into a clean, graduated container. Measure the total amount of oil removed. This measurement will help determine how much fresh oil to add to the new compressor to maintain proper system oil charge.
7. 7

   Prepare new compressor
   Remove shipping caps from new compressor ports. Drain factory oil from new compressor and measure quantity. Add the correct amount of new POE oil suitable for R-1234yf systems based on total system capacity and oil removed from old compressor. Refer to Rivian specifications for total system oil capacity.
   ℹ️Electric compressors require specific POE oil compatible with R-1234yf refrigerant. Do not use traditional PAG oil types designed for belt-driven compressors.
8. 8

   Install new compressor
   Position new compressor into mounting bracket, aligning all mounting holes. Hand-start all mounting bolts to ensure proper thread engagement. Torque mounting bolts to specification in a cross-pattern sequence to ensure even clamping force.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
9. 9

   Install new O-rings on refrigerant lines
   Remove old O-rings from AC line fittings and discard. Install new R-1234yf compatible O-rings on both suction and discharge line fittings. Lightly coat new O-rings with fresh POE oil to aid installation and ensure proper seal.
   ⚠Only use O-rings specifically designed for R-1234yf systems. Incompatible O-rings can leak or degrade.
10. 10

    Connect refrigerant lines
    Remove caps from compressor ports. Connect suction and discharge lines to compressor, ensuring fittings are fully seated. Torque AC line fittings to specification, being careful not to over-tighten which could damage O-rings or threads.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Reconnect electrical connections
    Reconnect the clutch connector to the compressor and install the connector bolt to specification. Carefully align and connect the orange high voltage connector to the compressor, ensuring it locks fully into place with an audible click.
    Torque spec

    Clutch Connector Bolt8 Nm (6 lb-ft)
12. 12

    Evacuate and recharge AC system
    Connect vacuum pump and manifold gauges to AC service ports. Evacuate system to 500 microns or lower and hold vacuum for 30 minutes to verify system integrity. If vacuum holds, proceed to recharge system with correct amount of R-1234yf refrigerant per Rivian specifications using approved charging equipment.
    ⚠If system will not hold vacuum, there is a leak that must be repaired before charging with refrigerant.
13. 13

    Reinstall underbody panels
    Reinstall all front underbody access panels that were removed for compressor access. Ensure all fasteners are properly tightened. Lower vehicle from jack stands.
14. 14

    Restore vehicle electrical systems
    Remove high voltage lockout device and follow Rivian procedures to re-energize HV system. Reconnect 12V auxiliary battery. Clear any diagnostic codes related to AC system using Rivian diagnostic software.

Reassembly

1. Ensure all electrical connectors are fully seated and locked, especially the orange HV connector
2. Verify all AC line fittings are torqued to specification with new O-rings installed
3. Confirm proper system oil charge based on measurements taken during removal
4. Double-check that HV safety lockout has been removed before attempting to energize vehicle

Verification

• Start vehicle and activate AC system through climate controls
• Verify compressor engages and runs smoothly without unusual noise or vibration
• Check for cold air output from cabin vents within 2-3 minutes of operation
• Use electronic leak detector to check all AC line connections for refrigerant leaks
• Monitor AC system pressures with manifold gauges to confirm proper operation (typical: 30-50 PSI low side, 200-300 PSI high side at ambient temperature)
• Verify no high voltage fault codes are present in vehicle diagnostics
• Run system for 15 minutes and recheck all connections for leaks or oil seepage
• Confirm proper clutch operation if equipped with cycling clutch

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