AC Hose - High Side

This procedure covers the removal and replacement of the high side AC hose on a 2024 Rivian EDV 500 delivery van, including refrigerant recovery and system recharge.

Warnings

Tools required

Parts

• AC high side hose assembly × 1 — Use OEM Rivian specification
• AC line O-ring seal kit × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As required per system specification
• PAG oil for R-1234yf systems × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery using battery disconnect procedure in service manual
3. Verify high voltage system is disabled - check instrument cluster for HV system shutdown confirmation
4. Allow AC system to stabilize to ambient temperature (minimum 30 minutes after last operation)
5. Connect R-1234yf recovery machine and verify machine is certified and within calibration date
6. Document current refrigerant charge amount during recovery for recharge reference
7. Remove engine compartment covers or access panels as needed to access AC compressor and condenser connections
8. Take photos of routing and bracket positions for high side hose before removal

Procedure

1. 1

   Recover AC refrigerant
   Connect the AC recovery machine to both the high and low side service ports. Follow machine manufacturer procedures to fully recover all refrigerant from the system. Record the amount of refrigerant and oil recovered. Ensure system pressure reads 0 PSI on both high and low sides before proceeding.
2. 2

   Disconnect high voltage interlock
   Locate the HVAC high voltage connector near the AC compressor. Remove the orange safety lock tab and disconnect the HV connector. Secure the connector away from the work area. Wait 5 minutes for capacitors to discharge before proceeding.
3. 3

   Remove compressor to condenser connection
   Locate the high side hose connection at the AC compressor discharge port. Use the appropriate AC line disconnect tool to release the quick-connect fitting. If using threaded fittings, support the compressor port with a backup wrench while loosening the hose fitting. Cap the compressor port immediately to prevent contamination.
4. 4

   Remove condenser to hose connection
   Access the high side hose connection at the condenser outlet. Release any retaining clips or brackets securing the hose. Use the AC line disconnect tool for quick-connect fittings or appropriate wrenches for threaded connections. Support the condenser fitting to prevent damage. Cap the condenser port immediately.
5. 5

   Release hose routing brackets
   Follow the high side hose along its routing path and remove all mounting brackets, clips, and cable ties securing it to the vehicle structure. Note the position of any grommets or insulators for reassembly. On the EDV 500, the hose typically routes along the front bulkhead with 3-4 mounting points.
6. 6

   Remove high side hose assembly
   Carefully extract the high side hose from the engine compartment, noting its routing path through any body openings or around other components. Inspect the removed hose for signs of damage, wear, or contamination that may indicate the cause of failure.
7. 7

   Inspect system components
   With the hose removed, inspect both the compressor discharge port and condenser inlet port for damage, corrosion, or debris. Check O-ring sealing surfaces for scratches or pitting. Inspect mounting brackets for cracks or damage. Replace any damaged components before installing new hose.
8. 8

   Prepare new hose assembly
   Remove the new high side hose from packaging. Install new O-rings on all fittings, ensuring they are the correct size and material for R-1234yf systems. Lightly lubricate O-rings with the specified PAG oil. Remove protective caps only immediately before connection.
9. 9

   Route new hose assembly
   Route the new high side hose along the same path as the original, ensuring it does not contact sharp edges, hot surfaces, or moving components. Install all grommets and insulators in their original positions. Verify adequate clearance to surrounding components throughout the suspension travel range.
10. 10

    Connect hose to condenser
    Remove the cap from the condenser port. Align the hose fitting with the condenser connection and push firmly (for quick-connect) or thread carefully (for threaded fittings) until fully seated. For threaded connections, tighten to manufacturer specification using a torque wrench and backup wrench. Verify the connection is secure.
11. 11

    Connect hose to compressor
    Remove the cap from the compressor discharge port. Connect the high side hose to the compressor using the same technique as the condenser connection. Ensure the fitting is fully engaged and properly torqued if threaded. Double-check that O-rings are properly seated.
12. 12

    Install mounting brackets
    Secure the high side hose to all mounting brackets and clips along its routing path. Ensure the hose is properly supported to prevent vibration and stress on the fittings. Install new cable ties as needed, but do not over-tighten as this can damage the hose.
13. 13

    Vacuum and leak test system
    Connect the AC service equipment to both high and low side ports. Evacuate the system to 29+ inches of mercury vacuum for a minimum of 45 minutes. After evacuation, close valves and monitor vacuum for 30 minutes. Vacuum should hold steady with no more than 1 inch loss, indicating no leaks.
14. 14

    Recharge AC system
    Using the R-1234yf recovery/recharge machine, charge the system with the specified amount of refrigerant (refer to underhood label or service manual for exact specification). Add the appropriate amount of PAG oil to compensate for oil lost with the old hose (typically 1-2 oz). Verify charge amount matches specification.
15. 15

    Reconnect high voltage and restore power
    Reconnect the HVAC high voltage connector, ensuring it clicks into place. Install the orange safety lock tab. Reconnect the 12V auxiliary battery. Clear any diagnostic trouble codes using the Rivian service software or scan tool.

Reassembly

1. Reinstall any engine compartment covers or panels removed for access
2. Verify all tools and equipment are removed from vehicle
3. Ensure no refrigerant leaks are present at new connections
4. Verify high side hose has proper clearance and is not contacting other components

Verification

• Start the vehicle and enable the AC system at maximum cooling setting
• Verify AC compressor engages and operates smoothly without unusual noise
• Check that high and low side pressures are within normal operating range (high side typically 180-250 PSI, low side 25-40 PSI at ambient temperature)
• Use electronic leak detector or UV light to inspect all new connections for refrigerant leaks
• Verify cold air output temperature at center vents reaches 40-45°F within 5 minutes
• Check for proper operation of all HVAC modes and temperature settings
• Confirm no warning lights or diagnostic codes are present related to HVAC or AC system
• Visually inspect high side hose for proper routing and secure mounting after test drive
• Document refrigerant charge amount and any findings in service records

More procedures for this vehicle