AC Compressor Oil Add

This procedure covers adding oil to the electric AC compressor system on the 2025 Rivian EDV 500, requiring partial refrigerant recovery and system evacuation.

Warnings

Tools required

Parts

• Electric AC compressor PAG oil (POE or PAG-S specific for electric compressors) × 1 — Use Rivian OEM specification - typically POE RL-68H for EV systems
• AC service port caps × 2 — Use OEM specification
• High voltage interlock service plug cover × 1 — Use OEM specification

Fluids

• Electric AC Compressor Oil (POE or PAG-S type) — 0.25 qt

Preparation

1. Verify the vehicle has been stationary for at least 30 minutes and AC system is off
2. Park vehicle on level surface and engage parking brake
3. Wear high voltage safety gloves and verify they are in good condition with no tears or holes
4. Access the Service Mode through the vehicle's touchscreen: Settings > Service > Service Mode
5. Wait for vehicle systems to fully power down (approximately 5 minutes)
6. Open front hood and locate the HV battery service disconnect
7. Remove the HV service disconnect plug per Rivian service manual instructions
8. Wait mandatory 5 minutes for high voltage capacitors to discharge
9. Use HV multimeter to verify 0 volts on all HV bus bars before proceeding
10. Place HV warning tags on steering wheel and service disconnect location
11. Identify AC compressor location (front of vehicle, driver side of frunk area)
12. Verify refrigerant type using refrigerant identifier - must be R-1234yf
13. Record ambient temperature and current AC system pressures if possible

Procedure

1. 1

   Connect recovery equipment
   Connect the R-1234yf recovery machine hoses to the AC system high and low pressure service ports. High pressure port is located on the AC line near the condenser (larger line), low pressure port is on the suction line near the compressor (smaller line). Ensure hose connections are tight and leak-free. Verify recovery tank has adequate capacity for approximately 2.2 lbs of refrigerant.
2. 2

   Recover refrigerant
   Start the recovery machine and recover all refrigerant from the AC system. Monitor the recovery process until the machine indicates recovery is complete (typically when system pressure remains stable at vacuum for 2-3 minutes). Record the amount of refrigerant recovered and the amount of oil recovered in the machine's separator. If less than 1.5 lbs refrigerant recovered, investigate for system leaks before proceeding.
3. 3

   Disconnect AC compressor electrical connector
   Locate the electric AC compressor on the driver side of the frunk area. Disconnect the electrical connector from the compressor by pressing the release tab and pulling straight out. Inspect connector terminals for corrosion or damage. Clean with electrical contact cleaner if necessary.
4. 4

   Access compressor service port
   Identify the oil service port on the AC compressor body. On Rivian electric compressors, this is typically a separate 1/4 inch SAE flare fitting on the compressor housing. Some models may require oil addition through the suction port. Clean the area around the port thoroughly to prevent contamination. If no dedicated oil port exists, proceed to add oil through the suction line connection.
5. 5

   Calculate required oil quantity
   Calculate the amount of oil to add based on Rivian specifications and oil recovered during refrigerant recovery. Standard practice: if system oil capacity is 4.0 oz and recovery machine collected 1.5 oz, add approximately 2.5 oz to restore system. Consult Rivian service data for exact compressor oil capacity. For oil top-off without component replacement, typically add 2-3 oz. Verify oil type is compatible with electric compressor (POE RL-68H or equivalent Rivian-approved oil).
6. 6

   Inject compressor oil
   Using the AC compressor oil injector tool, draw the calculated amount of fresh POE oil into the injector. Connect the injector to the compressor oil service port or suction line. Slowly inject the oil into the compressor while rotating the compressor shaft by hand if accessible (some electric compressors are sealed and cannot be rotated manually). Inject oil slowly over 2-3 minutes to allow proper distribution. Disconnect injector tool and cap the service port immediately.
7. 7

   Reconnect AC lines and electrical
   If any AC lines were disconnected, reconnect them now ensuring proper O-ring condition (replace O-rings if disturbed). Hand-tighten AC line fittings, then torque to specification (typically 15-20 ft-lb for AC line fittings, but consult service data as no specific torque values provided). Reconnect the compressor electrical connector ensuring it clicks into place securely.
8. 8

   Evacuate AC system
   Connect vacuum pump to AC manifold gauges. Open manifold valves and start vacuum pump. Evacuate system to minimum 29.5 inHg vacuum. Continue evacuation for at least 30 minutes after reaching target vacuum. Monitor for vacuum decay - if vacuum drops more than 1 inHg in 10 minutes after pump shutoff, there is a leak that must be repaired before recharging.
9. 9

   Recharge AC system
   With system under vacuum and manifold valves closed, prepare to charge system with R-1234yf. Connect refrigerant supply to center port of manifold. Place electronic scale under refrigerant container and zero the scale. Charge system with 2.2 lbs of R-1234yf (verify exact specification in Rivian service data). Charge liquid refrigerant through high side with system off, then switch to low side vapor charging if needed. Monitor scale to ensure accurate charge weight.
10. 10

    Restore high voltage system
    Verify all AC service work is complete and all tools are removed from vehicle. Reinstall the HV service disconnect plug ensuring it seats fully and locks into place. Remove HV warning tags from vehicle. Close front hood securely.
11. 11

    Power up and test system
    Enter vehicle and power on the vehicle systems. Exit Service Mode through the touchscreen. Allow vehicle to complete startup sequence. Turn AC system to maximum cooling with fan on high. Let system run for 5 minutes to distribute oil throughout the system. Monitor compressor operation - it should engage and cycle normally without unusual noise.
12. 12

    Check system performance
    With AC running at maximum, measure vent temperature using digital thermometer. At 75°F ambient, expect vent temps of 40-45°F. Check high side pressure (should be 150-250 psi depending on ambient) and low side pressure (should be 25-45 psi). Verify pressures are within normal range. Listen for abnormal compressor noise which could indicate oil starvation or contamination.

Reassembly

1. Install new service port caps on high and low pressure ports
2. Verify all electrical connections are secure and properly seated
3. Ensure HV service disconnect is fully installed and locked
4. Confirm all panels and covers in frunk area are reinstalled
5. Clear any service mode indicators from vehicle display

Verification

• Start vehicle and run AC system for 10 minutes at maximum cooling
• Verify vent temperature reaches 40-45°F at 75°F ambient temperature
• Confirm AC compressor cycles on and off normally with temperature demands
• Check for refrigerant leaks using UV light if dye was added, or electronic leak detector
• Verify no unusual noises from compressor during operation
• Confirm system high side pressure is 150-250 psi and low side is 25-45 psi with system running
• Test AC performance in both driver and passenger zones
• Verify no warning lights or AC-related fault codes in vehicle system
• Road test vehicle and confirm AC maintains cooling performance under load

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