AC Recharge

This procedure covers the complete evacuation, leak testing, and recharging of the R-1234yf air conditioning system on the 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• R-1234yf refrigerant × 1 — Use OEM specification
• PAG oil for electric compressor × 1 — Use Rivian-approved PAG oil
• AC service port caps × 2 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is in service mode using Rivian diagnostic software
3. Disable climate control system through vehicle interface
4. Allow AC system to stabilize at ambient temperature for at least 30 minutes
5. Verify refrigerant type using identifier tool before beginning service
6. Document ambient temperature and initial system pressures
7. Inspect underbody AC lines and condenser for visible damage or leaks

Procedure

1. 1

   Connect diagnostic equipment
   Connect Rivian diagnostic software to vehicle OBDII port. Access HVAC module and check for stored fault codes related to AC system. Record any codes present, particularly refrigerant pressure sensor faults or compressor errors. Clear codes only after documenting.
2. 2

   Locate and access service ports
   Locate low-pressure service port on accumulator/dryer near front passenger side frame rail and high-pressure port on liquid line near condenser. Remove plastic caps from both ports. The EDV 500 uses 1/4 inch SAE connections with R-1234yf-specific fittings to prevent cross-contamination.
3. 3

   Recover existing refrigerant
   Connect R-1234yf recovery machine to both service ports. Follow machine manufacturer procedure to completely recover all refrigerant from system. Machine should indicate when recovery is complete and display total refrigerant weight recovered. Record this weight for comparison to specification (approximately 2.2 lbs for EDV 500). If significantly low, suspect a leak.
4. 4

   Perform vacuum test
   Using recovery machine or separate vacuum pump, evacuate system to at least 29.5 inches Hg vacuum. Close all valves and observe vacuum gauge for 30 minutes minimum. Vacuum should not drop more than 1 inch Hg. If vacuum drops significantly, system has a leak that must be repaired before recharging.
5. 5

   Perform nitrogen pressure test if needed
   If vacuum test failed, pressurize system with dry nitrogen to 50 psi maximum (never exceed 75 psi on electric vehicle AC systems). Use electronic leak detector to check all connections, particularly at compressor body, condenser inlet/outlet, evaporator connections under dash, and all mechanical joints. Mark any leak locations for repair.
   ⚠Do not exceed 75 psi during nitrogen testing. Electric compressor seals may be damaged by excessive pressure.
6. 6

   Verify compressor oil level
   With system empty, check service records or measure oil removed during recovery. Electric compressors in Rivian vehicles use specific PAG oil compatible with R-1234yf. If more than 2 oz of oil was recovered, add equivalent amount of new oil. If less than 1 oz recovered, add 2 oz fresh oil through low-side port using oil injector.
7. 7

   Final evacuation
   Perform final system evacuation for minimum 45 minutes at 29.5 inches Hg or better. This removes all air and moisture from system. For new or opened systems, extend evacuation time to 60 minutes. Close machine valves and verify vacuum holds for 10 minutes before proceeding to recharge.
8. 8

   Recharge system with refrigerant
   Using R-1234yf recharge machine, add refrigerant to system per Rivian specification: 2.2 lbs ± 0.5 oz (approximately 1000 grams). Charge through low-side port with vehicle off. Machine will automatically stop at programmed weight. Do not overcharge - excess refrigerant will cause high head pressure and poor cooling.
9. 9

   Disconnect equipment and install caps
   Carefully disconnect manifold gauges or recharge machine from service ports. Immediately install new or clean service port caps and tighten finger-tight plus 1/8 turn. These caps are critical for preventing refrigerant leakage over time.
10. 10

    Initial system startup
    Using diagnostic software, command climate control system to maximum cooling with fresh air mode and high blower speed. Monitor live data for compressor clutch engagement (if applicable), refrigerant pressure readings, and evaporator temperature. Low-side pressure should stabilize between 25-45 psi and high-side between 175-250 psi depending on ambient temperature.
11. 11

    Verify system operation
    Allow system to run for minimum 15 minutes. Use thermometer to measure center vent temperature - should reach 38-42°F with ambient temperature above 70°F. Check for proper condenser fan operation (should cycle on at approximately 200 psi high-side pressure). Listen for unusual compressor noises or vibration.
12. 12

    Perform final leak check
    With system running at full pressure, use electronic leak detector to check all service ports, connections, and previously identified problem areas. Pay special attention to compressor shaft seal and condenser connections. Any detected leaks must be repaired and system re-evacuated and recharged.
13. 13

    Document and clear codes
    Using diagnostic software, verify no active fault codes in HVAC module. Clear any historic codes that were resolved during service. Record final system pressures, vent temperature, and total refrigerant weight added in service documentation. Update vehicle service history with AC service completion.

Reassembly

1. Ensure all service port caps are securely installed to prevent contamination and leakage
2. Return vehicle to normal operating mode through diagnostic software
3. Restore any underbody panels or covers removed for access to AC components

Verification

• Center dash vents should produce air temperature between 38-42°F at maximum cooling with ambient above 70°F
• Low-side pressure should read 25-45 psi and high-side 175-250 psi at idle with AC on (varies with ambient temperature)
• No refrigerant leaks detected at any connection points with electronic leak detector
• Condenser fans cycle appropriately based on system pressure
• No unusual noise or vibration from electric compressor during operation
• HVAC module shows no active fault codes in diagnostic software
• System maintains consistent vent temperature during 20-minute test drive with varied ambient conditions

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