AC Hose - High Side

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

Warnings

Tools required

Parts

• AC high-side hose assembly × 1 — Use OEM specification
• AC line O-ring seal kit × 1 — Use OEM specification
• AC system PAG oil × 1 — Use manufacturer-specified PAG oil for R-1234yf systems
• AC line mounting clips × 1 — Replace any damaged clips

Preparation

1. Ensure you have valid EPA 609 certification for mobile AC work before proceeding
2. Park vehicle on level surface and engage parking brake
3. Verify refrigerant type using refrigerant identifier - confirm R-1234yf before recovery
4. Disconnect 12V auxiliary battery and wait 3 minutes for system capacitor discharge
5. Verify high-voltage system is powered down (orange HV indicator light off on dash)
6. Raise and secure vehicle on lift or jack stands if underside access is needed
7. Allow AC system to equalize to ambient temperature (minimum 1 hour since last operation)
8. Document pre-repair AC system performance for post-repair comparison
9. Take photos of routing and mounting points for high-side hose before removal

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to service ports. Verify machine oil level and filter condition. Recover all refrigerant from the system according to machine manufacturer instructions. Record the amount of refrigerant and oil recovered - this information is needed for proper recharge. Ensure recovery is complete by monitoring gauges for at least 5 minutes to confirm no pressure rise.
2. 2

   Remove front bumper cover and grille assembly
   Remove plastic clips securing upper grille trim. Remove fasteners along top of bumper cover (typically 6-8 bolts). Remove wheel well liner clips on both sides to access side mounting points. Disconnect any electrical connectors for sensors or lighting. With assistance, carefully pull bumper cover forward and remove from vehicle. Set aside in protected area to prevent damage.
3. 3

   Access AC condenser and high-side line connections
   Locate the AC condenser mounted behind the front grille area. Identify the high-side hose connection at the condenser outlet (smaller diameter line). Remove any protective covers or shields blocking access to the AC line connections. Take detailed photos of hose routing, bracket positions, and electrical sensor locations for reference during reassembly.
4. 4

   Disconnect high-side hose at condenser
   Use AC line disconnect tool to separate high-side hose from condenser outlet. Have shop towels ready to catch residual oil. Inspect the condenser-side fitting for damage or corrosion. Remove and discard the O-ring seals from the connection. Cap or plug the condenser outlet immediately to prevent contamination from entering the system.
5. 5

   Trace and release high-side hose routing
   Follow the high-side hose from condenser toward the compressor, noting all mounting brackets and clips. Release hose from any securing clips along the frame rail or body panels. On the EDV 500, the line typically routes along the passenger side of the motor compartment. Disconnect any temperature or pressure sensors attached to the high-side line, noting connector orientations.
6. 6

   Disconnect high-side hose at compressor
   Locate the high-side connection at the electric compressor discharge port. Clean area around connection with lint-free cloth to prevent contamination. Use appropriate wrench to loosen the flare or threaded connection at the compressor. Have shop towels ready for residual oil drainage. Remove and discard O-ring seals. Immediately cap the compressor discharge port to prevent moisture and debris entry.
7. 7

   Remove high-side hose assembly
   Carefully extract the high-side hose assembly from the vehicle, ensuring no damage to surrounding components. Watch for any additional clips or brackets that may still be securing the line. Drain any residual refrigerant oil from the old hose into a graduated container and measure the amount. This oil quantity must be replaced during reassembly.
8. 8

   Inspect system components and prepare new hose
   Inspect condenser and compressor ports for damage, corrosion, or debris. Check compressor mounting for security and inspect electrical connections for damage. Verify the new high-side hose matches the original in length, fittings, and routing configuration. Remove protective caps from new hose only when ready to install. Lubricate new O-rings with appropriate PAG oil before installation.
9. 9

   Install new high-side hose at compressor
   Install new lubricated O-rings onto compressor discharge fitting. Remove protective cap from new high-side hose compressor end. Route hose in same path as original, ensuring no kinks or sharp bends. Connect hose to compressor discharge port, hand-tightening first to ensure proper thread engagement. Tighten connection to proper specification (refer to service information if torque spec becomes available). Do not over-tighten as this can damage sealing surfaces.
10. 10

    Route and secure high-side hose
    Follow the routing documented in photos from disassembly. Secure hose in all original mounting clips and brackets, ensuring proper clearance from moving parts, heat sources, and sharp edges. Verify hose has adequate slack to accommodate any motor mount movement or thermal expansion. Reconnect any pressure or temperature sensors to the high-side line, ensuring connectors click securely into place.
11. 11

    Connect high-side hose at condenser
    Install new lubricated O-rings onto condenser outlet fitting. Remove protective cap from condenser-side end of new hose. Align hose fitting with condenser outlet and push firmly until connection seats completely (you should feel or hear a click with quick-disconnect fittings, or thread engagement with threaded fittings). Verify connection is secure by attempting to pull hose away from condenser - it should not separate. Tighten threaded connections to specification if applicable.
12. 12

    Reinstall front bumper and grille assembly
    Reconnect any electrical connectors for sensors or lighting in the bumper area. With assistance, align bumper cover to mounting points and push into position. Install all fasteners along top edge, sides, and lower mounting points. Reinstall wheel well liner clips. Reinstall grille and trim pieces. Verify all clips and fasteners are secure and bumper has proper panel gaps.
13. 13

    Vacuum and leak test AC system
    Reconnect 12V auxiliary battery. Connect vacuum pump to AC service ports. Pull vacuum on system to at least 29 inches Hg (500 microns preferred) for minimum 45 minutes. Isolate vacuum pump and monitor system for 30 minutes - vacuum should hold steady with less than 1 inch drop, indicating no leaks. If vacuum does not hold, locate and repair leak before proceeding. Document vacuum test results.
14. 14

    Recharge AC system with refrigerant
    Using R-1234yf recovery/recharge machine, add the amount of refrigerant recovered during step 1, plus any additional refrigerant specified by service information (typically 1.5-2.5 lbs total system capacity for EDV 500 - verify exact specification). Add measured amount of PAG oil to replace what was drained from old hose. Follow recharge machine instructions for proper charging procedure. Verify system pressures stabilize within normal operating range.
15. 15

    Performance test and leak verification
    Start vehicle and activate climate control system to maximum cooling. Allow system to operate for at least 10 minutes. Using manifold gauges, verify high-side pressure is within specification (typically 200-300 psi depending on ambient temperature). Verify low-side pressure is appropriate (typically 30-50 psi). Check discharge air temperature at cabin vents - should achieve 40-50°F below ambient. Use electronic leak detector or UV light (if UV dye was added) to inspect all connections for leaks. Document final system pressures and temperatures.

Reassembly

1. Ensure all AC line connections are properly torqued and secured with appropriate clips
2. Verify all electrical connectors for AC pressure and temperature sensors are fully seated
3. Confirm high-side hose has proper clearance from all moving components and heat sources
4. Double-check that front bumper cover is properly aligned with correct panel gaps
5. Verify all protective shields and covers removed during access are reinstalled

Verification

• Perform complete AC system performance test with gauges - high and low side pressures must be within specification
• Verify cabin discharge air temperature achieves at least 40°F below ambient temperature
• Use electronic leak detector to verify no refrigerant leaks at new high-side hose connections
• Inspect for any unusual noises from AC system during operation
• Verify AC compressor cycles on and off appropriately based on system demand
• Check that all warning lights on instrument cluster are off and no AC-related fault codes are present
• Test drive vehicle and verify AC system maintains proper cooling performance under load
• Provide customer with documentation of refrigerant amount added and system test results

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