AC High Pressure Switch

This procedure replaces the AC high pressure switch on a 2024 Rivian EDV 500, requiring refrigerant recovery, removal of underbody panels, and system recharge.

Warnings

Tools required

Parts

• AC high pressure switch × 1 — Use OEM Rivian specification
• AC high pressure line seal/O-ring kit × 1 — Use OEM Rivian specification
• R-1234yf refrigerant × 1 — As needed to recharge system

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal
3. Follow Rivian service procedures to disconnect high voltage system using manual service disconnect located in rear underbody compartment
4. Wait minimum 5 minutes after HV disconnect for capacitor discharge
5. Raise and secure vehicle on jack stands at manufacturer-specified lift points
6. Remove front underbody aero panels to access AC components (retained by push clips and 10mm fasteners)
7. Connect R-1234yf recovery machine and recover all refrigerant from AC system per machine instructions
8. Document refrigerant quantity recovered for recharge reference

Procedure

1. 1

   Locate AC high pressure switch
   The AC high pressure switch is mounted on the high pressure AC line near the condenser assembly on the driver side of the front underbody. Identify the electrical connector and the switch body threaded into the AC line.
2. 2

   Disconnect electrical connector
   Press the locking tab on the AC high pressure switch electrical connector and pull straight away from the switch. Verify no visible corrosion on pins. Set connector aside where it will not be damaged.
3. 3

   Clean switch area
   Clean the area around the AC high pressure switch and line fitting thoroughly to prevent contamination from entering the AC system during removal. Use compressed air to remove any debris.
4. 4

   Remove old AC high pressure switch
   Using a 13mm socket or appropriate wrench, carefully unthread the AC high pressure switch from the high pressure line fitting. Turn counterclockwise to remove. Some residual refrigerant may escape during removal.
5. 5

   Inspect and replace O-ring seal
   Remove the old O-ring seal from the switch port on the AC line. Inspect the sealing surface for damage, corrosion, or debris. Clean the port threads and sealing surface thoroughly. Install new O-ring from seal kit onto the new high pressure switch.
6. 6

   Apply lubricant to O-ring
   Apply a thin coat of refrigerant oil (POE oil compatible with R-1234yf) to the new O-ring to ensure proper sealing and prevent damage during installation.
7. 7

   Install new AC high pressure switch
   Thread the new AC high pressure switch into the high pressure line fitting by hand to ensure proper thread engagement. Once hand-tight, use a 13mm socket or wrench to tighten. Since no specific torque value is provided, tighten to manufacturer specifications found in Rivian service manual, typically 8-12 ft-lbs for AC switches. Do not overtighten as this may damage the fitting or switch.
8. 8

   Reconnect electrical connector
   Push the electrical connector onto the new AC high pressure switch until the locking tab clicks into place. Verify secure connection by gently pulling on the connector.
9. 9

   Evacuate AC system
   Connect vacuum pump to AC system service ports. Evacuate the system to a minimum of 29.5 inches of mercury vacuum for at least 30 minutes to remove all moisture and air. Monitor for vacuum loss which would indicate a leak.
10. 10

    Perform vacuum hold test
    Close all valves and shut off vacuum pump. Monitor vacuum gauge for 10 minutes. Vacuum should hold steady with minimal loss. Any significant vacuum loss indicates a leak that must be addressed before recharging.
11. 11

    Recharge AC system
    Using the R-1234yf recharge machine, add refrigerant to the system according to the quantity recovered (typically 1.8-2.2 lbs for EDV 500, verify in service manual). Follow machine instructions for proper recharge procedure.
12. 12

    Reinstall underbody panels
    Reinstall front underbody aero panels in reverse order of removal. Ensure all push clips are fully seated and 10mm fasteners are secure.
13. 13

    Reconnect electrical systems
    Reconnect high voltage system using manual service disconnect. Reconnect 12V battery negative terminal. Clear any diagnostic codes related to HV disconnect using Rivian diagnostic software.

Reassembly

1. Ensure all underbody panels are properly secured with all fasteners and clips installed
2. Verify no tools or parts left in vehicle underbody area
3. Lower vehicle from jack stands safely

Verification

• Start vehicle and enable AC system to maximum cooling with fan on high
• Allow system to run for 5 minutes and verify compressor engages and disengages normally
• Monitor high pressure switch electrical signal using Rivian diagnostic software if available
• Verify AC system produces cold air at cabin vents (approximately 40-50°F at max cooling)
• Check for refrigerant leaks at high pressure switch connection using electronic leak detector
• Verify no warning lights or AC-related diagnostic trouble codes present
• Confirm AC system pressures are within normal range (high side 200-250 psi, low side 25-40 psi at idle in 75°F ambient)

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