This procedure covers the removal and replacement of the AC compressor on the 2024 Rivian EDV 500 dual motor electric delivery van, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC Compressor × 1 — Use OEM Rivian specification
• AC line O-rings × 4 — Use OEM specification
• PAG oil for electric compressor × 1 — PAG 46 or Rivian-specified electric compressor oil
• R-1234yf refrigerant × 1 — As required per system specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Wear appropriate high voltage personal protective equipment (PPE)
3. Access the HV battery disconnect following Rivian service procedures and apply lockout/tagout
4. Wait minimum 5 minutes after HV disconnect for capacitor discharge
5. Verify zero voltage at HV junction box using insulated multimeter
6. Connect AC recovery machine and fully recover R-1234yf refrigerant from system
7. Record amount of refrigerant recovered for recharge reference
8. Remove front underbody splash shield for access to compressor area

Procedure

1. 1

   Verify high voltage isolation
   Using a CAT III rated digital multimeter, verify zero voltage between HV positive and negative terminals at the compressor electrical connector. Document voltage reading as 0V before proceeding.
2. 2

   Disconnect compressor electrical connector
   Press the release tab on the high voltage connector at the AC compressor. Carefully pull connector straight back to disconnect. Secure connector away from work area to prevent accidental contact or contamination.
   ⚠Even with HV system disabled, treat all orange cables as energized until verified otherwise.
3. 3

   Remove clutch connector bolt
   Locate the clutch connector bolt on the compressor body. Using appropriate socket, remove the bolt completely. Keep bolt for reinstallation.
   Torque spec

   Clutch Connector Bolt8 Nm (6 lb-ft)
4. 4

   Disconnect AC refrigerant lines
   Using a line wrench or appropriate tool, carefully loosen the AC line fittings at the compressor. There are typically two lines (suction and discharge). Once loosened, remove fittings completely. Cap all open ports immediately to prevent moisture and debris entry. Inspect and discard old O-rings.
   ⚠Residual refrigerant or oil may escape when lines are disconnected. Wear eye protection and ensure ventilation.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove AC compressor mounting bolts
   Locate all AC compressor mounting bolts (typically 3-4 bolts). Support the compressor weight with one hand while removing the final bolts. Remove all mounting bolts and retain for reinstallation.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
6. 6

   Remove AC compressor from vehicle
   Carefully maneuver the AC compressor out of the mounting bracket. Route past any nearby harnesses or coolant lines. Lower compressor from vehicle and place on clean work surface. Drain any remaining oil from old compressor and measure quantity for reference.
7. 7

   Prepare new AC compressor
   Remove new compressor from packaging. Verify correct part number matches vehicle specification. Check that shipping plugs are installed in all ports. Drain shipping oil from new compressor if present. Add fresh PAG oil to new compressor in the amount equal to what was drained from old compressor (typically 100-150ml for electric compressor).
   ℹ️Use only PAG oil specified for electric AC compressors. Standard PAG oil may not be electrically compatible.
8. 8

   Install new AC compressor
   Remove shipping plugs from new compressor ports. Carefully position new compressor into mounting bracket, routing past harnesses and lines. Align mounting holes with bracket. Install all mounting bolts hand-tight first, then torque in star pattern to specification.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
9. 9

   Install new O-rings and connect AC lines
   Install new O-rings on both AC line fittings. Lightly coat O-rings with fresh PAG oil to aid installation and prevent damage. Carefully thread AC line fittings onto compressor ports by hand to avoid cross-threading. Once hand-tight, torque fittings to specification using line wrench.
   ⚠Cross-threading aluminum fittings will damage threads and require component replacement. Always start threads by hand.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Install clutch connector bolt
    Position clutch connector and install bolt. Torque to specification.
    Torque spec

    Clutch Connector Bolt8 Nm (6 lb-ft)
11. 11

    Reconnect compressor electrical connector
    Inspect electrical connector for damage or corrosion. Align connector and push firmly until it clicks into place. Verify connector is fully seated and locking tab is engaged.
12. 12

    Reinstall underbody panels
    Reinstall front underbody splash shield and any removed trim panels. Ensure all fasteners are properly secured.
13. 13

    Vacuum test AC system
    Connect vacuum pump to AC service ports. Evacuate system to 29+ inches Hg vacuum. Hold vacuum for minimum 30 minutes. Monitor for vacuum decay which would indicate a leak. System should hold vacuum with less than 1 inch Hg loss over 30 minutes.
    ⚠If system will not hold vacuum, locate and repair leak before charging with refrigerant.
14. 14

    Recharge AC system
    Using R-1234yf recovery/recharge machine, charge system with refrigerant to manufacturer specification (use recovered amount as baseline, typically 800-1200g for EDV 500). Follow machine prompts for proper charging procedure. Add any additional PAG oil as required by machine calculation.

Reassembly

1. Remove lockout/tagout devices from HV battery disconnect
2. Reconnect HV battery following Rivian service procedures
3. Perform visual inspection of all connections and fasteners
4. Clear any diagnostic trouble codes that may have been stored during service

Verification

• Start vehicle and enable AC system
• Verify compressor engages and operates smoothly without abnormal noise
• Monitor AC performance - should produce cold air at vents within 2-3 minutes
• Check all AC line connections for leaks using electronic leak detector
• Verify no refrigerant odor present in cabin or engine compartment
• Use scan tool to verify no AC system fault codes present
• Confirm compressor clutch cycles properly under varying load conditions
• Check system pressures match manufacturer specification (typically 25-45 PSI low side, 150-250 PSI high side at idle with AC on MAX)

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