This procedure covers the removal and replacement of the AC condenser on a 2023 Rivian EDV 500, including refrigerant recovery, condenser removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-ring kit × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — Use OEM specification
• PAG oil for R-1234yf systems × 1 — Use OEM specification
• Front bumper cover clips × 10 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
3. Verify high voltage system is in safe mode via instrument cluster
4. Document refrigerant charge amount using AC machine before recovery
5. Place fender covers to protect painted surfaces during front end disassembly

Procedure

1. 1

   Recover AC refrigerant
   Connect R-1234yf recovery machine to low and high side service ports. Follow machine instructions to fully recover refrigerant from the system. Record the amount recovered for recharge reference. Allow system to pull vacuum for 5 minutes to verify no residual pressure remains.
2. 2

   Remove front bumper cover
   Remove T30 Torx screws securing upper bumper cover to front fascia (6 locations). Remove 10mm bolts securing lower bumper cover (4 locations). Disconnect fog light connectors if equipped. Use panel removal tools to release clips along wheel well liner edges. Carefully pull bumper cover forward and remove from vehicle. Set aside on protected surface.
3. 3

   Remove active grille shutters
   Disconnect electrical connector from active grille shutter motor. Remove three 10mm bolts securing shutter assembly to radiator support. Carefully lift shutter assembly upward and out of mounting position. Set aside to access condenser.
4. 4

   Disconnect AC lines from condenser
   Using appropriate wrench, carefully loosen AC line fittings at condenser inlet and outlet connections. Remove fittings completely and immediately cap open ports with clean plugs to prevent moisture and debris entry. Remove and discard old O-rings from line fittings. Note routing of lines for reinstallation.
5. 5

   Remove condenser mounting hardware
   Remove condenser mounting bolts from upper brackets (2 locations). Remove lower condenser mounting bolts from radiator support (2 locations). Carefully note position of any rubber isolators or spacers for reinstallation.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
6. 6

   Remove condenser assembly
   Carefully tilt top of condenser forward and lift upward to clear lower mounting tabs. Maneuver condenser out from between radiator and front support structure. Inspect radiator fins for damage during removal. Remove any remaining mounting hardware or brackets from old condenser if reusing.
7. 7

   Prepare new condenser
   Remove protective caps from new condenser ports immediately before installation. Drain shipping oil from new condenser into measuring container. Add appropriate amount of fresh PAG oil to new condenser based on manufacturer specifications (typically 2-3 oz if replacing condenser only). Verify all mounting brackets are transferred from old condenser if required.
8. 8

   Install new condenser
   Carefully position new condenser between radiator and front support, ensuring lower tabs engage properly. Tilt condenser back to vertical position. Verify rubber isolators are properly positioned at all mounting points. Install condenser mounting bolts finger-tight at all four locations, then torque to specification in cross pattern.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
9. 9

   Install new O-rings and connect AC lines
   Lubricate new O-rings with clean PAG oil and install on AC line fittings. Verify O-rings are properly seated in grooves. Remove caps from condenser ports immediately before connection. Thread AC line fittings onto condenser ports by hand to ensure proper thread engagement. Torque fittings to specification using proper wrench technique.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reinstall active grille shutters
    Position active grille shutter assembly into mounting location on radiator support. Install three 10mm bolts and tighten securely. Reconnect electrical connector to shutter motor. Verify shutter motor moves freely without obstruction.
11. 11

    Reinstall front bumper cover
    Position front bumper cover to vehicle and align mounting points. Reconnect fog light connectors if equipped. Press bumper cover firmly to engage clips along wheel well liner edges. Install 10mm bolts at lower mounting locations and tighten securely. Install T30 Torx screws at upper mounting locations. Verify all gaps and panel alignment are correct.
12. 12

    Evacuate and recharge AC system
    Connect AC machine to service ports. Pull vacuum on system for minimum 45 minutes. System should hold vacuum without loss for 10 minutes to confirm no leaks. Recharge system with documented amount of R-1234yf refrigerant (typically 1.8-2.2 lbs total system capacity). Add UV dye if leak detection capability is desired.
13. 13

    Reconnect battery and initialize system
    Reconnect 12V battery negative terminal. Power on vehicle to accessory mode. Allow HVAC system to perform self-test. Clear any stored fault codes related to AC system disconnect. Run blower motor at low speed for 2 minutes before operating AC compressor.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Inspect all AC line connections for signs of oil leakage after recharge
3. Confirm front bumper cover is securely fastened with no loose clips or fasteners
4. Test active grille shutter operation through vehicle diagnostics if available

Verification

• Start vehicle and set AC to maximum cold and high blower speed
• Verify compressor engages and cold air is produced within 2-3 minutes
• Check center vent discharge temperature reaches 40-45°F within 5 minutes
• Inspect all AC line connections for frost formation indicating proper refrigerant flow
• Use leak detector around all connections to verify no refrigerant leaks
• Verify active grille shutters open and close properly during AC operation
• Monitor system pressures: low side should be 25-45 PSI, high side 200-275 PSI at idle with 75°F ambient
• Test drive vehicle and verify AC maintains cold temperature under load

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