This procedure involves removing the HVAC evaporator core from the 2024 Rivian EDV 500, requiring dashboard and HVAC housing disassembly to access the evaporator located behind the instrument panel.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• HVAC housing gasket/seal kit × 1 — Use OEM specification
• AC O-rings for refrigerant lines × 1 — Use OEM specification
• Cabin air filter × 1 — Use OEM specification
• PAG oil for AC system × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — Use OEM specification
• Dashboard trim clips (assorted) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Access vehicle settings through center display and enable Service Mode to disable high-voltage system
3. Disconnect 12V battery negative terminal and wait minimum 10 minutes
4. Use certified AC recovery machine to fully evacuate refrigerant from system and record amount recovered
5. Remove front seats to provide working room and access to lower dashboard fasteners
6. Disconnect climate control electrical connectors accessible from under dashboard
7. Document all electrical connector positions with photographs
8. Remove driver and passenger side lower dashboard panels

Procedure

1. 1

   Remove instrument cluster and center display
   Remove the instrument cluster bezel by releasing clips at the top edge. Disconnect the cluster electrical connectors behind the panel. Remove the center touchscreen display by removing the four Torx screws at corners and carefully disconnecting the multi-pin connectors from the rear of the display unit. Support the display as you disconnect to prevent cable strain.
2. 2

   Remove steering column covers and column mounting
   Remove upper and lower steering column covers by releasing retaining clips. Disconnect the column electrical connectors including steering angle sensor and column lock motor. Remove the four steering column mounting bolts and carefully lower the column assembly, supporting it with a suitable stand or securing it to prevent hanging by electrical connections.
3. 3

   Disconnect refrigerant lines at firewall
   From the engine compartment, locate the AC refrigerant lines entering the firewall near the passenger side. Cap the evaporator inlet and outlet lines immediately after disconnection to prevent moisture and contamination entry. Remove the refrigerant line mounting bolts and carefully pull the lines through the firewall grommet. Measure and record any oil that drains from the lines.
4. 4

   Remove passenger side dashboard end cap and glove box
   Remove the passenger side dashboard end cap by pulling firmly from the rear edge to release clips. Open glove box and remove the damper arms from both sides. Remove glove box mounting screws (typically 4-6 screws) and remove the entire glove box assembly to access the HVAC housing behind it.
5. 5

   Disconnect HVAC electrical connectors and remove cabin air filter
   Locate and disconnect all HVAC-related electrical connectors including blower motor, actuator motors for blend doors, temperature sensors, and evaporator temperature sensor. Remove the cabin air filter access door and extract the cabin air filter. Note the filter orientation for proper reinstallation.
6. 6

   Remove blower motor assembly
   Disconnect the blower motor electrical connector. Remove the blower motor mounting screws (typically 3-4 screws) and carefully extract the blower motor and fan assembly from the HVAC housing. The blower motor may require rotation or specific angle to clear the housing opening.
7. 7

   Remove main dashboard support beam
   Locate and remove all fasteners securing the main dashboard support beam to the A-pillars, center tunnel, and firewall. This typically involves 8-12 bolts and may require access from multiple angles. Have an assistant support the dashboard structure as you remove the final fasteners. The beam must be removed or significantly loosened to access HVAC housing mounting points.
8. 8

   Separate HVAC housing halves
   Remove all screws and clips securing the HVAC housing upper and lower sections together (typically 10-15 fasteners around the perimeter). Carefully separate the housing halves, being mindful of any remaining electrical connections or actuator linkages. The housing may have alignment dowels that require careful manipulation to separate.
9. 9

   Extract evaporator core from housing
   Once the housing is open, carefully lift the evaporator core from its mounting position. Note the orientation of the core, location of the expansion valve, and routing of the temperature sensor. Drain any residual oil from the old evaporator into a graduated container and measure the quantity. Inspect the evaporator mounting area for debris, leaves, or signs of moisture damage.
10. 10

    Prepare and install new evaporator
    Install new O-rings on the refrigerant line connections, lubricating them with appropriate PAG oil. Add the measured amount of PAG oil (plus any additional specified by evaporator manufacturer) to the new evaporator core. Position the new evaporator in the housing with correct orientation, ensuring the expansion valve is properly seated and temperature sensor is correctly positioned.
11. 11

    Reassemble HVAC housing
    Install new housing gaskets/seals as required. Carefully align the housing halves, ensuring no wires or actuator linkages are pinched. Install all housing fasteners in a cross-pattern to ensure even pressure and proper sealing. Verify all blend door actuators move freely and are correctly positioned before fully tightening all fasteners.
12. 12

    Reconnect refrigerant lines
    Route the refrigerant lines through the firewall grommet from the engine compartment. Connect the lines to the evaporator using new O-rings lubricated with PAG oil. Ensure the lines are properly seated and install all mounting hardware. Verify there is no strain or kinking in the refrigerant line routing.

Reassembly

1. Reinstall blower motor assembly and reconnect electrical connector
2. Install new cabin air filter in correct orientation
3. Reconnect all HVAC electrical connectors, referring to photos taken during disassembly
4. Reinstall dashboard support beam with all fasteners properly torqued
5. Reinstall glove box assembly and passenger side trim panels
6. Reinstall steering column to proper position and reconnect all electrical connections
7. Reinstall instrument cluster and center touchscreen display
8. Reinstall all lower dashboard panels and driver/passenger trim pieces
9. Reinstall front seats and reconnect seat electrical connections
10. Reconnect 12V battery negative terminal

Verification

• Perform complete AC system vacuum test: evacuate system to 29.9 inches Hg and hold for minimum 45 minutes to verify no leaks
• If vacuum holds, charge system with manufacturer-specified amount of R-1234yf refrigerant
• Exit Service Mode through vehicle infotainment system to restore high-voltage system
• Start vehicle and test all HVAC functions including temperature control, fan speeds, and air distribution modes
• Verify cold air production at all vents with temperature measurements (should reach 40-45°F at center vents within 10 minutes)
• Check for proper condensate drainage from evaporator drain tube under vehicle
• Perform UV leak detection test at all refrigerant connections
• Verify all dashboard functions, displays, and controls operate normally
• Check for any unusual noises from HVAC system during operation
• Verify no refrigerant odor in cabin and no oily residue at vents

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