AC Hose - Low Side

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

Warnings

Tools required

Parts

• AC low-side hose assembly × 1 — Use OEM Rivian specification
• AC line O-ring kit × 1 — Use OEM specification for R-1234yf system
• R-1234yf refrigerant with PAG oil × 1 — Use OEM specification
• UV dye (if not pre-mixed) × 1 — R-1234yf compatible

Preparation

1. Verify EPA 609 certification for R-1234yf refrigerant handling is current
2. Park vehicle on level surface and apply parking brake
3. Ensure HVAC system is off and vehicle is in Park mode
4. Allow AC system to stabilize to ambient temperature (minimum 30 minutes after last operation)
5. Identify the low-side service port (typically on larger diameter line near firewall on passenger side)
6. Document pre-service refrigerant charge amount and system pressures using manifold gauges
7. Verify recovery machine is calibrated and contains sufficient empty storage for vehicle capacity
8. Place fender covers and floor protection to catch any residual oil or refrigerant

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to both high and low-side service ports. Follow machine manufacturer's procedure to fully recover refrigerant from the system. Record the amount recovered for comparison during recharge. Ensure system reaches atmospheric pressure and wait 5 minutes to verify no pressure rise, indicating complete recovery.
2. 2

   Remove lower front fascia panel
   Remove the lower front fascia panel to access the AC lines routing from the compressor. Release push-pin fasteners along the bottom edge and remove bolts securing the panel to the frame rails. Carefully disconnect any electrical connectors for sensors mounted in the panel. Set panel aside in a protected area.
3. 3

   Access the AC compressor area
   Locate the AC compressor mounted in the front drive unit compartment on the passenger side. The low-side hose connects to the compressor outlet and routes toward the evaporator at the firewall. Note the routing path and any securing clips or brackets before removal.
4. 4

   Disconnect low-side hose at compressor
   Using the appropriate AC line disconnect tool, depress the quick-connect collar or loosen the threaded fitting at the compressor outlet. If threaded, use a backup wrench to prevent compressor port rotation. Remove the connection and immediately cap both the compressor port and hose end to prevent contamination and moisture entry. Inspect and discard old O-rings.
5. 5

   Release hose securing clips
   Follow the low-side hose routing toward the firewall, releasing any spring clips, P-clamps, or bracket fasteners securing the hose to the frame or body. On the EDV 500, there are typically 3-4 securing points along the passenger side frame rail. Keep all hardware organized for reinstallation.
6. 6

   Disconnect low-side hose at evaporator connection
   Locate the evaporator connection at the firewall, typically near the passenger side HVAC housing. This may require accessing from inside the cargo area behind interior panels. Use the AC line disconnect tool to separate the fitting. Cap the evaporator port immediately to prevent moisture intrusion into the evaporator core.
7. 7

   Remove low-side hose assembly
   Carefully extract the complete low-side hose assembly from the vehicle, noting its routing path through frame channels and around other components. Inspect the removed hose for signs of abrasion, contamination, or damage that caused the failure. Check surrounding areas for interference points that may have caused hose damage.
8. 8

   Prepare new low-side hose
   Unpack the new AC low-side hose assembly and verify part number matches OEM specification for EDV 500. Install new O-rings at both connection points, lightly lubricating with clean refrigerant oil from the system. Do not use petroleum-based lubricants. Ensure O-rings are properly seated in their grooves without twists or damage.
9. 9

   Install new low-side hose
   Route the new hose assembly following the exact path of the original, ensuring adequate clearance from sharp edges, moving components, and high voltage cables (orange conduit). Connect the hose to the evaporator port first, ensuring the quick-connect or threaded fitting is fully seated and secure. Then route toward the compressor.
10. 10

    Connect hose to compressor
    Attach the low-side hose to the AC compressor outlet, ensuring proper O-ring seating and full engagement of the quick-connect or complete threading of the fitting. If threaded, hand-tighten then use torque wrench to achieve proper specification (note: specific torque not available in database - follow OEM service manual specification). Use backup wrench on compressor port.
11. 11

    Secure hose with clips and brackets
    Reinstall all securing clips, P-clamps, and brackets along the hose routing path. Ensure the hose is properly supported at all OEM mounting points to prevent vibration damage and maintain clearance from surrounding components. Verify no contact with frame edges or potential pinch points.
12. 12

    Evacuate AC system
    Connect vacuum pump to AC system service ports. Evacuate system to at least 500 microns and maintain for minimum 30 minutes. Monitor vacuum gauge - if vacuum does not hold steady, there is a leak that must be repaired before proceeding. For optimal moisture removal, evacuate for 45-60 minutes on this vehicle's system volume.
13. 13

    Recharge AC system
    Using the R-1234yf recharge machine, introduce refrigerant to the system per OEM specification (typically 1.8-2.2 lbs for EDV 500 - verify on underhood label). Charge through the low-side port only with engine/vehicle systems off. Add UV dye if not pre-mixed in refrigerant. Verify charge amount matches recovered amount plus any loss from component.
14. 14

    Reinstall front fascia panel
    Reconnect any electrical connectors to sensors in the lower fascia panel. Position panel and secure with bolts to frame rails and push-pin fasteners along the bottom edge. Ensure proper alignment and all fasteners are fully engaged.

Reassembly

1. Double-check all AC line connections are secure and properly torqued
2. Verify all electrical connectors are properly seated and locked
3. Confirm no tools or parts are left in the engine compartment or cargo area
4. Ensure all panel fasteners and clips are reinstalled

Verification

• Place vehicle in Ready mode and turn AC system to maximum cooling
• Using manifold gauges, verify system pressures are within normal range (low side: 25-45 PSI, high side: 180-250 PSI at ambient 75°F)
• Check for proper compressor operation and clutch/electric motor engagement
• Inspect all connections with electronic leak detector or UV light to verify no refrigerant leaks
• Verify cold air temperature at center vents reaches 38-42°F after 5 minutes of operation
• Listen for unusual noises from compressor or hissing sounds indicating leaks
• Test system operation through multiple cycles and verify automatic shutoff functions properly
• Document final system charge amount and pressure readings for service records
• Road test vehicle to verify AC performance under load and confirm no warning lights or error codes related to HVAC system

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