Replace the AC hose assembly on a 2023 Rivian EDV 500, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• R-1234yf refrigerant × 1 — Use OEM specification
• PAG oil for R-1234yf systems × 1 — Use OEM specification
• AC line sealing caps × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disable high voltage system using service disconnect located in front trunk
3. Wait 5 minutes after HV disconnect, then verify zero voltage at HV junction box with multimeter
4. Place 12V battery disconnect tool on negative terminal to prevent module wake-up
5. Allow AC system to equalize for at least 10 minutes if recently operated
6. Verify R-1234yf recovery machine is properly calibrated and has sufficient tank capacity
7. Document refrigerant charge weight during recovery for accurate recharge
8. Identify which AC hose assembly requires replacement (suction, discharge, or liquid line)

Procedure

1. 1

   Recover AC refrigerant
   Connect R-1234yf recovery machine to AC service ports (low and high side). Follow recovery machine instructions to completely evacuate refrigerant from system. Record the amount of refrigerant recovered for recharge reference. Allow recovery process to complete until machine indicates system is empty and pressures stabilize at zero.
2. 2

   Remove front underbody shield
   Remove fasteners securing front underbody aerodynamic shield to access AC lines. Remove plastic push clips and bolts securing shield. Carefully lower shield away from vehicle. This provides access to AC hoses routed along front subframe.
3. 3

   Access AC line routing area
   For EDV 500, AC lines route from compressor mounted on front drive unit through firewall to HVAC module. Remove any necessary trim panels in wheel well or engine compartment to access full length of hose assembly. Document hose routing with photos before removal.
4. 4

   Disconnect AC hose at compressor end
   Using appropriate line wrenches, carefully loosen AC hose fittings at compressor connections. Support hose assembly to prevent stress on fittings. Once loose, disconnect fittings and immediately cap open ports with sealing caps to prevent moisture and contamination entry. Remove and discard old O-rings from fittings.
5. 5

   Disconnect AC hose at HVAC module end
   Locate AC hose connection points at HVAC module or condenser (depending on which hose is being replaced). Use line wrenches to disconnect fittings at module end. Immediately cap all open ports. Note orientation and position of hose routing brackets and clips.
6. 6

   Remove hose mounting brackets
   Remove bolts or clips securing AC hose assembly to body, frame, or motor mounts. EDV 500 uses several vibration-isolating mounting points along hose length. Keep all mounting hardware organized for reinstallation. Carefully work hose assembly free from routing path.
7. 7

   Extract old AC hose assembly
   Carefully maneuver old AC hose assembly out of vehicle, paying attention to routing path through congested areas. Note exact routing including any pass-throughs, grommets, or heat shields. This documentation is critical for proper installation of new assembly.
8. 8

   Prepare new AC hose assembly
   Unpack new AC hose assembly and verify it matches old part exactly in length, fitting types, and mounting bracket locations. Lubricate new O-rings with proper PAG oil for R-1234yf systems. Install new O-rings on all fittings. Keep protective caps on hose ends until ready to connect.
9. 9

   Route new AC hose assembly
   Following documented routing path, carefully position new AC hose assembly into vehicle. Ensure hose follows exact same path as original, maintaining proper clearances from heat sources, moving components, and sharp edges. Temporarily secure with mounting brackets in middle of routing path first.
10. 10

    Connect AC hose at compressor
    Remove caps from new hose fittings and compressor ports. Verify O-rings are properly seated and lubricated. Hand-thread fittings onto compressor ports, then tighten with line wrenches. Follow proper tightening sequence if multiple connections are present. Do not overtighten aluminum fittings.
11. 11

    Connect AC hose at HVAC module
    Connect opposite end of hose assembly to HVAC module or condenser fittings. Remove caps, verify O-ring placement, hand-thread, and tighten with line wrenches. Ensure hose is not twisted or kinked along entire length.
12. 12

    Secure all mounting brackets
    Install and tighten all AC hose mounting brackets and clips. Ensure hose is properly supported at all mounting points to prevent vibration and fatigue. Verify adequate clearance from all moving parts and hot surfaces (motor components, exhaust routing if applicable).
13. 13

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to 29+ inches Hg vacuum. Maintain vacuum for minimum 45 minutes to remove air and moisture. Monitor vacuum gauge for any pressure rise indicating leaks. If system holds vacuum, proceed to recharge.
14. 14

    Recharge AC system
    Using refrigerant scale and proper R-1234yf charging equipment, recharge system with amount recovered earlier (typically 1.5-2.0 lbs for EDV 500, verify on underhood label). Add appropriate amount of PAG oil if significant oil was lost with old hose. Charge through low-side port only with system off initially, then run system to complete charge.
15. 15

    Reinstall underbody components
    Reinstall front underbody aerodynamic shield and any removed trim panels. Ensure all fasteners are properly secured. Reconnect 12V battery and restore high voltage system following proper startup sequence.

Reassembly

1. Reinstall all underbody panels and trim pieces removed during access
2. Verify all AC line mounting brackets are secure and hose has proper clearances
3. Reconnect 12V battery and restore high voltage system per Rivian service procedures
4. Clear any diagnostic trouble codes related to AC system or HV disconnect

Verification

• Start vehicle and activate AC system to maximum cooling
• Verify compressor clutch engages (or verify compressor operation on electric compressor system)
• Check for proper cooling performance at cabin vents (should reach 40-45°F at max setting)
• Use AC leak detector or UV light to inspect all new connections for refrigerant leaks
• Monitor AC system pressures with manifold gauges during operation (should show typical values: 25-45 PSI low side, 150-250 PSI high side at ambient temperature)
• Verify no unusual noises from AC system during operation
• Check for proper system cycling and temperature control
• Test drive vehicle and verify AC performance under load
• Recheck all connections after initial operation for any signs of leakage

More procedures for this vehicle