Heat Pump System

This procedure covers the removal and replacement of the heat pump system on a 2023 Rivian EDV 500, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• Heat pump assembly × 1 — Use OEM specification
• Refrigerant line O-ring kit × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As specified by system capacity label
• PAG oil for R-1234yf systems × 1 — Use OEM specification
• Coolant line quick-connect seals × 1 — Use OEM specification
• High voltage connector seals × 1 — Use OEM specification

Fluids

• EV Battery/Motor Coolant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify vehicle is off and key fob is at least 20 feet away from vehicle
3. Chock rear wheels if lifting front of vehicle
4. Access the high voltage disconnect located in the front trunk (frunk) under the access panel
5. Don high voltage insulated gloves and safety glasses rated for electrical work
6. Remove the high voltage service disconnect plug and install lockout/tagout device
7. Wait minimum 5 minutes for capacitor discharge before proceeding
8. Verify zero voltage at heat pump electrical connector using high voltage multimeter
9. Remove underbody aero panels to access heat pump assembly mounting points
10. Place refrigerant recovery container and equipment in position
11. Ensure R-1234yf recovery machine is properly calibrated and certified

Procedure

1. 1

   Recover refrigerant from system
   Connect R-1234yf recovery machine to service ports located on the heat pump assembly. Follow recovery machine manufacturer instructions to completely evacuate all refrigerant from the system. Record the amount of refrigerant and oil recovered for proper recharge quantities. Ensure recovery is complete by monitoring system pressure reaching vacuum levels.
2. 2

   Disconnect high voltage harness
   Wearing high voltage gloves, locate the orange high voltage connector on the heat pump compressor. Depress the locking tab and carefully disconnect the high voltage harness. Cover the exposed connector with insulating tape. Secure the harness away from the work area.
3. 3

   Disconnect low voltage electrical connectors
   Identify and disconnect all low voltage electrical connectors attached to the heat pump assembly, including sensors, valves, and control modules. There are typically 4-6 connectors depending on configuration. Label each connector for proper reassembly.
4. 4

   Drain coolant from heat pump circuit
   Position coolant recovery container under heat pump coolant connections. Carefully disconnect the coolant supply and return lines from the heat pump using appropriate line disconnect tools. Allow coolant to drain completely into container. Expect approximately 2-3 quarts of coolant to drain. Cap open coolant lines to prevent contamination.
5. 5

   Disconnect refrigerant lines
   Using proper line wrench or flare nut wrench, disconnect the suction and discharge refrigerant lines from the heat pump assembly. Remove and discard all O-rings from the line connections. Cap all open refrigerant ports immediately to prevent moisture and contamination from entering the system.
6. 6

   Remove heat pump mounting bolts
   Locate all heat pump assembly mounting bolts, typically 6-8 bolts securing the unit to the vehicle frame. Support the heat pump assembly weight with a suitable jack or support stand. Remove all mounting bolts while supporting the assembly to prevent it from falling.
7. 7

   Remove heat pump assembly from vehicle
   With all connections and mounting bolts removed, carefully lower the heat pump assembly from its mounting location. Maneuver the assembly through the underbody area, being careful not to damage surrounding components or wiring. The assembly weighs approximately 40-50 pounds. Use assistance if needed.
8. 8

   Prepare new heat pump assembly
   Remove the new heat pump assembly from packaging. Verify part numbers match the original unit. Check that all ports have protective caps and that shipping brackets or restraints are removed. Add the specified amount of PAG oil to the new compressor if not pre-charged (verify with parts documentation).
9. 9

   Install new heat pump assembly
   Position the new heat pump assembly into the mounting location, using a jack or support stand for alignment. Install all mounting bolts hand-tight first to ensure proper alignment, then tighten in a cross-pattern to secure the assembly evenly. Note: Specific torque specifications not available in database - refer to service manual.
10. 10

    Connect refrigerant lines with new O-rings
    Install new O-rings on all refrigerant line connections, lightly lubricating with refrigerant oil. Remove caps from heat pump ports and line ends. Connect suction and discharge lines to the heat pump assembly. Tighten refrigerant line fittings to manufacturer specifications using proper flare nut wrenches to avoid damage.
11. 11

    Reconnect coolant lines
    Install new seals or O-rings on coolant quick-connect fittings. Connect coolant supply and return lines to the heat pump assembly, ensuring they click fully into place. Verify connections are secure by attempting to pull lines free.
12. 12

    Reconnect electrical connections
    Reconnect all low voltage electrical connectors to the heat pump assembly, referencing labels applied during disassembly. Ensure all connectors are fully seated and locking tabs are engaged. Remove insulating tape from high voltage connector and carefully reconnect the orange high voltage harness to the compressor, ensuring it clicks securely into place.
13. 13

    Evacuate and recharge refrigerant system
    Connect vacuum pump to system service ports and evacuate the system to 500 microns or lower. Hold vacuum for minimum 30 minutes to verify no leaks (vacuum should remain stable). Charge system with the amount of R-1234yf refrigerant recovered plus any additional needed to meet system capacity specifications on the vehicle label (typically 1.5-2.5 lbs total). Add PAG oil equivalent to amount removed during recovery.
14. 14

    Refill coolant system
    Access coolant reservoir and add EV Battery/Motor Coolant to replace the amount drained during heat pump removal. Use the vehicle's coolant fill procedure through the service menu to purge air from the system. Run the thermal management system bleeding cycle to ensure complete air removal.
15. 15

    Reinstall underbody panels and restore power
    Reinstall all underbody aero panels removed during disassembly. Remove lockout/tagout device from high voltage service disconnect. Reinstall high voltage service disconnect plug in the frunk access panel. Close all access panels securely.

Reassembly

1. Double-check all electrical connections are fully seated and secured
2. Verify all refrigerant and coolant connections are tight and properly sealed
3. Confirm no tools or parts were left in the work area or underbody
4. Ensure all protective covers and underbody panels are properly reinstalled

Verification

• Using the vehicle's service menu, run a complete thermal management system self-test
• Verify no error codes related to heat pump or thermal management system are present
• Use refrigerant leak detector to check all refrigerant connections for leaks
• Start vehicle and activate climate control in both heating and cooling modes, verifying proper operation
• Monitor system pressures on both high and low sides to ensure they are within normal operating range (typically 35-50 PSI low side, 150-250 PSI high side at idle)
• Check coolant level after system has run through several heating and cooling cycles
• Inspect all connections for coolant leaks while system is operating
• Verify heat pump compressor engages and disengages properly during climate control operation
• Perform a test drive to ensure normal climate control operation under various conditions
• Monitor thermal management system for at least 30 minutes of operation to ensure stable performance

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