AC Recharge

This procedure performs a complete AC system recharge on the 2024 Rivian EDV 500, including evacuation, leak testing, and refrigerant fill to proper specifications.

Warnings

Tools required

Parts

• R-1234yf refrigerant × 1 — Use OEM specification - approximately 1.8-2.2 lbs
• PAG 46 refrigerant oil (EV-compatible) × 1 — Use OEM specification - quantity as needed
• AC service port caps × 2 — High and low side
• UV dye for R-1234yf systems × 1 — Optional for leak detection

Preparation

1. Park vehicle in well-ventilated area away from ignition sources and open flames
2. Ensure vehicle is powered off completely and 12V battery is accessible
3. Verify R-1234yf recovery/recharge machine is properly calibrated and contains sufficient virgin refrigerant
4. Connect Rivian diagnostic scanner and document any HVAC-related fault codes
5. Verify ambient temperature is above 60°F (15°C) for accurate system testing
6. Inspect cabin air filter condition and replace if contaminated
7. Check battery state of charge is above 20% for accurate system performance testing

Procedure

1. 1

   Access AC service ports
   Open front hood and locate AC service ports on the liquid and suction lines near the front motor/compressor assembly. The low-side port (larger diameter) is typically on the suction line, and high-side port (smaller diameter) is on the liquid line. Remove protective caps from both service ports and inspect for contamination or damage. Clean port threads if necessary.
2. 2

   Verify system pressure and recover refrigerant
   Connect R-1234yf recovery machine hoses to both high and low side service ports. Check static pressure on both sides - system should show equal pressure when not operating. If pressure is zero, note this as it indicates a significant leak. Initiate refrigerant recovery cycle and allow machine to fully evacuate all refrigerant from the system. Record the amount of refrigerant recovered - compare to specification (typically 1.8-2.2 lbs). If recovered amount is significantly less than specification, major leak is present.
3. 3

   Perform initial leak detection
   With system depressurized, use electronic R-1234yf leak detector to scan all AC components including compressor housing, condenser, evaporator drains, service ports, and line connections. Pay special attention to areas showing signs of oil residue. If major leaks are detected at this stage, repairs must be completed before proceeding. Document all leak locations for post-service verification.
4. 4

   Vacuum system evacuation - initial pull
   Connect vacuum pump to AC machine and begin evacuation process. Pull vacuum to at least 500 microns (29.9 inches Hg). Monitor vacuum gauge and ensure system reaches target vacuum within 30-45 minutes. If system fails to reach proper vacuum, this indicates a leak or moisture contamination. Continue vacuum for minimum of 30 minutes once target vacuum is achieved to remove moisture from system.
5. 5

   Perform vacuum hold test
   Close all valves to isolate the AC system and shut off vacuum pump. Monitor vacuum level for 15 minutes minimum. System should not rise more than 50 microns during this period. If vacuum rises significantly, a leak is present and must be repaired before continuing. If vacuum holds steady, system integrity is confirmed.
6. 6

   Add refrigerant oil if required
   Calculate oil replacement needs based on recovered oil amount and any replaced components. Electric compressors in Rivian EDV require EV-compatible PAG 46 oil. If compressor was replaced, add manufacturer-specified amount (typically 3-4 oz). If only recharging, replace oil equal to amount removed during recovery. Inject oil through low-side port using oil injector tool before refrigerant charge.
7. 7

   Charge system with refrigerant - vapor phase
   Begin refrigerant charge process in vapor phase through low-side port only. With vehicle off, add approximately 50% of total refrigerant capacity in vapor form. Monitor pressure gauges - low side should rise to approximately 60-70 psi at 70°F ambient. This partial charge prepares system for liquid charging and prevents compressor damage. Add UV dye at this stage if performing leak detection enhancement.
8. 8

   Complete refrigerant charge - liquid phase
   Switch recharge machine to liquid phase charging. Power vehicle to READY mode to activate electric compressor. Add remaining refrigerant in liquid form through high-side port while compressor is running, monitoring weight on scale. Fill to exact specification from Rivian Service Portal (typically 1.8-2.2 lbs total). Do not overcharge - EV systems are sensitive to refrigerant quantity. Monitor pressures: low side should be 25-40 psi, high side 175-250 psi at idle with 70°F ambient.
9. 9

   Verify compressor operation and system pressures
   With system fully charged and vehicle in READY mode, set climate control to maximum cooling, recirculation mode, fan speed high, temperature to 60°F. Using diagnostic scanner, monitor electric compressor engagement, speed (should reach 3000-6000 RPM), and current draw. Verify low-side pressure stabilizes at 25-40 psi and high-side at 200-250 psi under full load. Listen for unusual compressor noises indicating oil starvation or internal damage.
10. 10

    Test cooling performance
    Insert digital thermometer into center dash vent with vehicle still in maximum cooling mode. Allow system to run for 10 minutes. Vent temperature should drop to 38-45°F with 70-80°F ambient temperature. Temperature drop (ambient minus vent) should be at least 30°F. If cooling performance is inadequate despite proper pressures, inspect for airflow restrictions, blend door issues, or internal evaporator problems.
11. 11

    Perform final leak detection
    With system pressurized and operating, perform complete leak check using electronic detector on all components, connections, and service ports. If UV dye was added, use UV light to inspect for fluorescent traces indicating leaks. Pay special attention to service port seals and any previously identified leak areas. Any detected leaks must be repaired and system recharged.
12. 12

    Clear fault codes and verify system data
    Using Rivian diagnostic scanner, access HVAC module and clear any stored fault codes related to low refrigerant pressure or system performance. Verify all system parameters are within normal range including evaporator temperature sensor, ambient temperature sensor, and refrigerant pressure sensors. Document final system pressures and temperatures for service records.

Reassembly

1. Install new service port caps on both high and low side ports with proper torque to prevent contamination
2. Verify all AC line connections are secure with no signs of refrigerant oil leakage
3. Ensure all wiring harnesses near AC components are properly routed and secured away from moving parts
4. Close hood and verify no tools or equipment remain in engine compartment

Verification

• Start vehicle and operate AC system for 5 minutes, verify center vent temperature reaches 38-45°F
• Confirm low-side pressure reads 25-40 psi and high-side reads 200-250 psi during operation at 70°F ambient
• Verify no unusual noises from electric compressor and smooth operation across all fan speeds
• Check diagnostic scanner shows no active or pending HVAC fault codes
• Perform visual inspection around all AC components for signs of refrigerant oil indicating leaks
• Test AC operation in various modes (MAX AC, Normal, ECO) to ensure proper function
• Verify defroster mode operates correctly with proper air distribution

More procedures for this vehicle