AC High Pressure Switch

This procedure covers the replacement of the AC high pressure switch on a 2023 Rivian EDV 500 electric delivery van, requiring partial AC system discharge and component access.

Warnings

Tools required

Parts

• AC high pressure switch × 1 — Use OEM Rivian specification
• O-ring seal for pressure switch × 1 — Use OEM Rivian specification
• R-1234yf refrigerant × 1 — As needed for recharge

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power down the vehicle completely using the touchscreen shutdown procedure
3. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitor discharge
4. Verify high voltage system is de-energized using Rivian service mode procedures
5. Allow AC system to equalize to ambient temperature if vehicle was recently operated
6. Document pre-service AC system pressures if system is still charged
7. Prepare AC recovery machine and ensure it has adequate capacity for R-1234yf
8. Verify you have the correct replacement pressure switch for the 2023 EDV 500 model

Procedure

1. 1

   Recover AC refrigerant
   Connect the AC recovery machine to the service ports on the high and low pressure lines. Follow machine manufacturer procedures to completely recover all R-1234yf refrigerant from the system. Record the amount recovered for recharge reference. Ensure system pressure reads 0 PSI on both high and low sides before proceeding.
2. 2

   Access front cargo area
   Open the front cargo compartment (frunk). The AC high pressure switch on the EDV 500 is located near the condenser assembly at the front of the vehicle. Remove the frunk liner panels by releasing the push-pin fasteners to gain access to the AC components.
3. 3

   Locate the AC high pressure switch
   Identify the AC high pressure switch on the liquid line near the condenser outlet. It will have a two-wire electrical connector and is threaded into the high pressure AC line. Take a photo for reference of routing and connector orientation.
4. 4

   Disconnect electrical connector
   Press the locking tab on the pressure switch electrical connector and carefully disconnect it. Inspect the connector terminals for corrosion or damage. Use a multimeter to verify no voltage is present at the connector.
5. 5

   Remove the old pressure switch
   Using a 13mm wrench or socket, carefully unscrew the AC high pressure switch from the fitting. Remove it completely along with the sealing O-ring. Inspect the threads in the fitting for damage or debris. Clean the threaded port thoroughly with a lint-free cloth.
6. 6

   Prepare new pressure switch
   Inspect the new AC high pressure switch and verify it matches the old unit. Install the new O-ring onto the switch. Apply a thin layer of appropriate refrigerant-compatible thread sealant to the threads of the new switch if specified by Rivian service procedures, or install dry if O-ring sealed.
7. 7

   Install new pressure switch
   Thread the new AC high pressure switch into the fitting by hand to ensure proper thread engagement. Tighten the switch to the specification provided in Rivian service documentation. If no torque specification is available, tighten to 10-15 ft-lbs or until the O-ring is compressed and seated, being careful not to over-tighten.
8. 8

   Reconnect electrical connector
   Reconnect the electrical connector to the new pressure switch, ensuring it clicks into place securely. Verify the connector locking tab is fully engaged and the wiring is properly routed away from any moving parts or sharp edges.
9. 9

   Evacuate the AC system
   Connect the vacuum pump to the AC service ports. Evacuate the system to at least 29 inches of mercury (Hg) vacuum. Maintain this vacuum for a minimum of 30 minutes. Monitor for any vacuum loss which would indicate a leak at the new switch or elsewhere in the system.
10. 10

    Perform leak test
    After successful evacuation, add a small amount of refrigerant (approximately 0.5 lbs) to the system. Use an electronic leak detector rated for R-1234yf to check for leaks at the new pressure switch and all surrounding connections. Pay special attention to the switch threads and O-ring seal.
11. 11

    Recharge AC system
    Using an approved refrigerant scale and charging equipment, recharge the AC system with the correct amount of R-1234yf refrigerant as specified on the vehicle underhood label (typically between 2.0-2.5 lbs for the EDV 500). Charge into the low pressure side only while the system is off, or follow Rivian-specific charging procedures.
12. 12

    Verify system operation
    Reconnect the 12V battery. Power up the vehicle and enter AC diagnostic mode if available through the service menu. Start the AC system and verify the high pressure switch is functioning correctly by monitoring system pressures. High side pressure should typically reach 150-250 PSI depending on ambient temperature. Verify the switch is sending proper signals to the vehicle computer.
13. 13

    Reassemble and final checks
    Reinstall the frunk liner panels and secure all push-pin fasteners. Perform a final visual inspection of all work performed. Clear any diagnostic trouble codes related to the AC system using Rivian service software. Test AC system operation through multiple cycles to ensure proper cooling and no abnormal behavior.

Reassembly

1. Ensure all frunk liner panels are properly secured with all fasteners in place
2. Verify no tools or parts were left in the frunk area
3. Confirm all electrical connectors are secured and properly routed
4. Document the amount of refrigerant added for service records

Verification

• Run the AC system for at least 10 minutes and verify proper cooling performance
• Check that high pressure switch operates within normal parameters (typically cuts out above 400 PSI if pressure becomes excessive)
• Use leak detector to perform final leak check around the new pressure switch
• Verify no AC-related diagnostic trouble codes are present
• Confirm high and low side pressures are within normal operating ranges for ambient temperature
• Test AC performance in both maximum cooling and economy modes
• Verify proper compressor cycling behavior controlled by the pressure switch

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