This procedure covers the removal and replacement of the AC evaporator in the 2023 Rivian EDV 500, requiring removal of the dashboard and HVAC housing.

Warnings

Tools required

Parts

• AC evaporator assembly × 1 — Use OEM specification
• Evaporator core seal kit × 1 — Use OEM specification
• AC expansion valve × 1 — Use OEM specification
• HVAC housing foam seals × 1 — Use OEM specification
• Dashboard fastener clips × 10 — Use OEM specification
• Refrigerant R-1234yf × 1 — As required per system capacity
• PAG oil for R-1234yf systems × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 3 minutes for airbag system capacitor discharge
3. Disable high voltage system using Rivian service mode procedures via center display
4. Recover AC refrigerant using certified R-1234yf recovery machine and document amount recovered
5. Remove front seats for improved dashboard access and workspace
6. Protect interior surfaces with seat covers and floor protection
7. Set up organized parts storage system with labeled containers for fasteners and clips

Procedure

1. 1

   Remove lower dashboard panels and trim
   Remove the lower dashboard trim panels on both driver and passenger sides using trim removal tools. Start at the bottom edges and work upward, releasing all plastic clips. Remove the knee bolster panels and any lower access covers. Disconnect any electrical connectors for courtesy lights or USB ports. Store all fasteners in organized containers.
2. 2

   Disconnect center console and screen assembly
   Remove the center console by removing all Torx fasteners (typically T20 and T25). Carefully disconnect all electrical harnesses from the center display screen, climate control panel, and wireless charging pad. Support the large center screen as you remove mounting fasteners and lift it away from the dashboard structure. Route all harnesses carefully to avoid damage.
3. 3

   Remove instrument cluster and steering column covers
   Remove the steering column upper and lower covers by releasing retaining clips. Remove the instrument cluster bezel and carefully extract the digital instrument cluster, disconnecting the main electrical connector at the rear. Lower the steering column to its lowest position for improved access to upper dashboard fasteners.
4. 4

   Disconnect all dashboard electrical connections
   Working systematically from left to right, disconnect all electrical connectors from the dashboard harness including: HVAC controls, passenger airbag connector, glove box light, all switch panels, and antenna connections. Label each connector with tape or take detailed photos for reassembly reference. Verify all connections are released before attempting dashboard removal.
5. 5

   Remove main dashboard mounting fasteners
   Locate and remove all dashboard mounting bolts and fasteners. These are typically located at the A-pillars, under the windshield cowl area, at the center tunnel, and at the sides near the doors. On the EDV 500, expect 12-16 main mounting points using T30 Torx and 10mm fasteners. Remove the windshield defroster grille panels to access upper fasteners.
6. 6

   Extract dashboard assembly
   With an assistant supporting the dashboard, carefully pull the dashboard assembly rearward away from the firewall. Watch for any remaining electrical connections or HVAC ducts that may still be attached. The dashboard is large and awkward; ensure adequate clearance past the steering column and shifter. Move the assembly to a protected work area on a padded surface.
7. 7

   Access and remove HVAC housing
   With the dashboard removed, the HVAC housing is now visible on the firewall. Disconnect the AC line connections at the evaporator inlet and outlet on the firewall (inside engine bay side). Cap all open AC lines immediately to prevent moisture ingress. Remove all HVAC housing mounting fasteners (typically 8-10 bolts) securing it to the firewall and passenger compartment structure.
8. 8

   Separate HVAC housing halves
   Place the HVAC housing on a clean workbench. Remove the housing cover fasteners (typically 12-15 screws around the perimeter). Carefully separate the housing halves, noting the position of all foam seals and air door linkages. The evaporator core will be visible inside the lower housing section along with the expansion valve.
9. 9

   Remove evaporator core and expansion valve
   Remove the retaining clips or brackets holding the evaporator core in place within the housing. Carefully lift the evaporator core out, taking care not to bend the delicate fins. Remove the expansion valve from the evaporator inlet. Inspect the housing interior for debris, leaves, or moisture damage. Clean the housing thoroughly before installing the new evaporator.
10. 10

    Install new evaporator core
    Add the specified amount of fresh PAG oil to the new evaporator core (typically 2-3 oz, verify with service data). Install new expansion valve to the evaporator inlet. Install all new foam seals provided in the seal kit to the evaporator mounting points. Carefully position the new evaporator into the lower housing section, ensuring all seals are properly seated and aligned with the housing ports.
11. 11

    Reassemble HVAC housing
    Apply new foam sealing strips around the housing mating surfaces if provided in the seal kit. Carefully rejoin the housing halves, ensuring all air door linkages are properly aligned and move freely. Install all housing cover fasteners in a cross-pattern to ensure even seal compression. Verify that blend doors and mode doors operate smoothly through their full range.
12. 12

    Reinstall HVAC housing to firewall
    Position the HVAC housing assembly back onto the firewall, aligning all mounting points and ensuring the evaporator tubes align with the firewall penetrations. Install all mounting fasteners and tighten evenly. From the engine bay side, reconnect the AC lines to the evaporator using new O-rings lubricated with refrigerant oil. Do not fully tighten AC fittings yet.
13. 13

    Reinstall dashboard assembly
    With assistance, carefully position the dashboard assembly back into the vehicle, ensuring all HVAC ducts align with the housing outlets. Install all main dashboard mounting fasteners at A-pillars, center tunnel, and side mounts. Reconnect all electrical connectors in reverse order of removal, referring to photos taken during disassembly. Reinstall instrument cluster, center display, and all trim panels.
14. 14

    Evacuate and recharge AC system
    Tighten all AC line fittings to proper specifications using a torque wrench. Connect AC vacuum pump to the system and evacuate for a minimum of 45 minutes to remove all air and moisture. Hold vacuum for 30 minutes to verify system integrity (vacuum should not decay). Recharge system with the documented amount of R-1234yf refrigerant recovered earlier, or per system specifications if replacement is needed.
15. 15

    Leak test and final checks
    Reconnect 12V battery and enable vehicle systems. Use electronic leak detector to check all AC connections for leaks. Start the vehicle and run the AC system through all modes (MAX AC, defrost, floor, etc.) at various fan speeds and temperatures. Monitor system pressures with manifold gauges to verify proper operation. Check for proper airflow from all vents and verify no unusual odors or sounds from the HVAC system.

Reassembly

1. Reinstall front seats and torque mounting bolts to specification
2. Verify all dashboard trim panels are fully seated with no gaps or rattles
3. Test all electrical functions including screen, climate controls, and courtesy lighting
4. Clear any diagnostic trouble codes that may have set during the repair
5. Verify airbag system shows no warnings on instrument cluster

Verification

• Confirm AC system produces cold air at all vents with temperature dropping to 40-45°F at max cooling
• Verify system pressures are within normal range (typically 25-35 psi low side, 200-250 psi high side at idle)
• Check that all blend doors and mode doors operate correctly through all climate control selections
• Confirm no refrigerant leaks detected at evaporator connections or throughout system
• Verify no musty odors or unusual sounds from HVAC system during operation
• Test defrost mode to ensure windshield fog clears rapidly
• Confirm cabin temperature reaches and maintains set point in auto mode

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