AC Hose Assembly

Replace the AC hose assembly on a 2024 Rivian EDV 500, including refrigerant recovery, hose removal, installation of new assembly, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM specification
• AC line O-rings × 1 — Use OEM specification
• AC system PAG oil × 1 — PAG 46 or per Rivian spec
• Refrigerant sealing caps × 4 — Use OEM specification

Fluids

• R-1234yf Refrigerant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Connect Rivian service tool and activate service mode to disable high voltage system
3. Verify high voltage system isolation using multimeter across HV battery terminals
4. Allow AC system to stabilize to ambient temperature for at least 30 minutes
5. Document refrigerant charge amount from vehicle label in engine bay
6. Connect R-1234yf recovery machine and verify machine is certified and calibrated
7. Raise and support vehicle on jack stands if accessing underbody hose routing
8. Remove front skid plate or belly pan if hose routing requires underbody access

Procedure

1. 1

   Recover refrigerant from AC system
   Connect recovery machine hoses to AC service ports. Start recovery process and allow machine to fully evacuate refrigerant from system. Document amount recovered for comparison to original charge. Once recovery is complete and system shows 0 PSI, wait 5 minutes and verify pressure does not rise, indicating complete recovery.
2. 2

   Remove cabin air intake assembly
   Remove front trunk liner panels to access HVAC components. Remove cabin air filter housing by releasing clips and disconnecting electrical connectors. Set aside to provide access to AC line connections at evaporator.
3. 3

   Disconnect AC lines at evaporator
   Locate AC hose connections at evaporator inlet and outlet. Using appropriate wrench, loosen connection fittings while holding backing nut stationary. Immediately cap open connections with sealing caps to prevent moisture entry and contamination. Remove and discard old O-rings from connections.
4. 4

   Access condenser connections
   Remove front fascia lower panels and air dam to access condenser area. Locate AC hose connections at condenser. Note routing of lines and any mounting brackets or clips securing hoses.
5. 5

   Disconnect AC lines at condenser
   Loosen condenser-side AC line connections using proper wrench technique. Cap all open ports immediately. Label or photograph hose routing before removal to ensure correct reinstallation path.
6. 6

   Remove AC hose assembly mounting hardware
   Remove all mounting brackets, clips, and fasteners securing AC hose assembly along its routing path. This may include underbody clips, frame mounting brackets, and vibration isolators. Keep track of all hardware for reinstallation.
7. 7

   Extract AC hose assembly
   Carefully maneuver AC hose assembly out of vehicle, following original routing path. Note any grommets, routing guides, or protective sleeves that must be transferred to new assembly. Inspect removed hose for damage location and cause to prevent recurrence.
8. 8

   Prepare new AC hose assembly
   Remove protective caps from new AC hose assembly only when ready to install. Inspect all fittings and connections for damage or debris. Install new O-rings on all connection points, lubricating with small amount of AC system PAG oil. Verify correct hose assembly part number matches vehicle specification.
9. 9

   Route and install new AC hose assembly
   Following documented routing path, carefully install new AC hose assembly into vehicle. Ensure hoses do not contact sharp edges, moving components, or high-temperature areas. Install all mounting brackets and clips finger-tight initially to allow for alignment adjustment.
10. 10

    Connect AC lines at condenser and evaporator
    Connect AC line fittings at condenser first, then at evaporator. Hand-tighten connections until O-rings seat, then use wrench to snug connections while holding backing nut. Do not overtighten aluminum fittings. Follow Rivian service manual specifications for final tightening if available.
11. 11

    Secure all mounting hardware
    With all connections made, verify proper hose routing and clearances throughout entire path. Tighten all mounting brackets and clips to secure hose assembly. Ensure no contact with bodywork or other components that could cause vibration noise or wear.
12. 12

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to at least 29 inches Hg vacuum. Maintain vacuum for minimum 30 minutes. After vacuum hold period, close service valves and observe vacuum gauge for 10 minutes. Vacuum should not drop more than 1 inch Hg, confirming system integrity.
13. 13

    Charge AC system with refrigerant
    Using recovery/recharge machine, add R-1234yf refrigerant to system per vehicle specification label. Typical charge is approximately 1.5-2.0 lbs for EDV 500, but verify exact amount on vehicle label. Add appropriate amount of PAG 46 oil if specified by hose replacement procedure. Monitor charging process and verify proper weight of refrigerant added.
14. 14

    Reinstall cabin air intake and body panels
    Reinstall cabin air filter housing and reconnect electrical connections. Replace front trunk liner panels. Reinstall front fascia components, air dam, and any underbody panels removed for access. Verify all clips and fasteners are secure.
15. 15

    Exit service mode and test AC operation
    Using Rivian service tool, deactivate service mode and restore high voltage system. Start vehicle and activate AC system at maximum cooling and fan speed. Monitor system pressures using manifold gauges. Verify pressures stabilize within normal range (typically 25-45 PSI low side, 200-300 PSI high side at ambient temperature). Check all connections for leaks using electronic leak detector or UV dye method.

Reassembly

1. Verify all trim panels and access covers are reinstalled and secure
2. Ensure no tools or parts are left in vehicle compartments
3. Reset any AC system fault codes using Rivian service tool
4. Document refrigerant charge amount and date on service record

Verification

• Confirm AC system produces cold air at all vents with fan at maximum speed
• Verify AC compressor engages and cycles normally without unusual noise
• Check system pressures stabilize within normal operating range after 10 minutes of operation
• Inspect all AC line connections for signs of refrigerant leakage using leak detector
• Test AC system operation through multiple cycles from off to maximum cooling
• Verify no refrigerant odor in cabin during operation
• Confirm ambient temperature and outlet temperature differential is at least 40°F
• Check for proper condensate drainage from evaporator drain

More procedures for this vehicle