Replace the AC pressure sensor on a 2024 Rivian EDV 500 electric delivery van to restore proper climate control system operation and refrigerant pressure monitoring.

Warnings

Tools required

Parts

• AC pressure sensor × 1 — Use OEM Rivian specification
• AC pressure sensor O-ring seal × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As needed to refill system
• PAG oil for R-1234yf systems × 1 — As specified by refrigerant loss

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key from cabin
3. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Connect scan tool and document any active AC system fault codes
5. Access service information to confirm AC pressure sensor location on the high-pressure AC line near the condenser
6. Ensure AC refrigerant recovery equipment is certified and calibrated
7. Open hood and secure in open position
8. Locate AC pressure sensor on the AC line assembly in the front compartment

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to the vehicle's service ports. Follow machine manufacturer instructions to fully recover all refrigerant from the system. Record the amount of refrigerant and oil recovered for later refilling. Ensure recovery is complete before proceeding.
2. 2

   Access AC pressure sensor
   Remove any protective covers or panels that obstruct access to the AC pressure sensor located on the high-pressure line near the condenser. On the EDV 500, this may require removing the front fascia lower trim panel. Use trim tools to avoid damage to clips.
3. 3

   Disconnect electrical connector
   Locate the electrical connector on the AC pressure sensor. Press the locking tab and carefully disconnect the wiring harness from the sensor. Inspect connector terminals for corrosion or damage.
4. 4

   Remove AC pressure sensor
   Using an appropriate wrench, carefully unthread the AC pressure sensor from the high-pressure line fitting. Turn counterclockwise to remove. Be prepared for residual refrigerant or oil to escape. Remove the sensor completely and set aside.
5. 5

   Inspect and clean mounting location
   Examine the sensor port threads on the AC line for damage, debris, or contamination. Clean threads with a lint-free cloth. Remove and discard the old O-ring seal from the port. Inspect for any signs of refrigerant leakage or corrosion around the fitting.
6. 6

   Prepare new AC pressure sensor
   Remove new AC pressure sensor from packaging. Install the new O-ring seal onto the sensor, ensuring it is properly seated in the groove. Lightly lubricate the O-ring with a small amount of PAG oil compatible with R-1234yf refrigerant to ease installation and prevent damage.
7. 7

   Install new AC pressure sensor
   Thread the new AC pressure sensor into the high-pressure line port by hand, turning clockwise. Tighten to manufacturer specification using a torque wrench. If no specific torque value is available, tighten firmly to ensure seal without over-tightening (typically 8-12 lb-ft for this type of sensor, but verify with service data).
8. 8

   Reconnect electrical connector
   Reconnect the wiring harness to the new AC pressure sensor. Ensure the connector locks securely with an audible click. Verify the connection is secure by gently pulling on the connector.
9. 9

   Reinstall access panels
   Reinstall any trim panels or protective covers that were removed for access. Ensure all clips and fasteners are properly seated and secure.
10. 10

    Vacuum and leak test system
    Connect AC vacuum pump to service ports. Evacuate the system for a minimum of 30 minutes to remove air and moisture. After evacuation, close service valves and observe vacuum gauge for 15 minutes. System should hold vacuum without dropping, indicating no leaks. If vacuum drops, locate and repair leak before proceeding.
11. 11

    Recharge AC system
    Using AC charging equipment, recharge the system with the correct amount of R-1234yf refrigerant as recorded during recovery or per manufacturer specifications. Add appropriate amount of PAG oil if significant oil was removed during recovery. Monitor pressure readings during charging process.
12. 12

    Reconnect battery and clear codes
    Reconnect the 12V battery negative terminal. Use scan tool to clear any stored AC system fault codes. Initialize AC pressure sensor if required by vehicle diagnostic system.

Reassembly

1. Ensure all electrical connections are secure and properly routed
2. Verify all panels and covers are reinstalled with proper clips engaged
3. Confirm no tools or parts are left in engine compartment
4. Double-check refrigerant charge level matches specifications

Verification

• Start vehicle and turn on AC system to maximum cooling
• Use scan tool to monitor AC pressure sensor readings in live data - should show realistic high and low side pressures
• Verify compressor engages and disengages properly based on pressure readings
• Check for proper cooling from cabin vents - temperature should drop to specified range within 5 minutes
• Inspect AC pressure sensor area for any signs of refrigerant leakage using leak detector
• Verify no AC system fault codes are present after test drive
• Confirm AC system cycles normally through various fan speeds and temperature settings

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