This procedure covers the removal and replacement of the AC compressor on a 2025 Rivian EDV 500 dual motor electric delivery van, including refrigerant recovery, electrical disconnection, and system recharge.

Warnings

Tools required

Parts

• AC compressor assembly × 1 — Use OEM Rivian specification
• AC line O-rings (set) × 1 — Use OEM specification
• PAG oil for electric compressor × 1 — POE oil, 150ml typical
• Compressor mounting bolts × 1 — Use OEM specification if damaged

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure HV battery is at less than 50% state of charge if possible to reduce electrical hazard
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system capacitor discharge
4. Follow Rivian HV lockout/tagout procedure: remove HV service disconnect under rear cargo area access panel
5. Verify HV system is de-energized using calibrated multimeter on HV junction box
6. Don high-voltage safety equipment including insulated gloves rated for 1000V
7. Remove lower front fascia panels to access compressor mounted in front motor compartment area
8. Connect R-1234yf recovery machine and fully recover all refrigerant from system per EPA regulations
9. Document amount of refrigerant and oil recovered for recharge reference
10. Take photos of electrical connector orientations and routing before disassembly

Procedure

1. 1

   Disconnect HV power to compressor
   Locate the high-voltage connector at the AC compressor. Depress the orange safety latch and slide it away from the connector body. Carefully pull the HV connector straight out from the compressor using both hands. Secure the connector end away from metal components using electrical tape or a protective cap.
2. 2

   Disconnect low-voltage control connector
   Locate the 12V control connector on the compressor body. Press the tab release and pull the connector straight out. This connector provides communication between the climate control module and compressor controller.
3. 3

   Remove AC line fittings
   Using appropriate wrenches, carefully loosen and remove the suction line (larger diameter) and discharge line (smaller diameter) fittings from the compressor. Have shop towels ready to catch residual oil. Immediately cap all open ports to prevent moisture and contamination entry. Remove and discard old O-rings from the line fittings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Remove compressor mounting bolts
   Locate the three mounting bolts securing the compressor to its bracket on the front motor assembly. Using a socket wrench, remove all mounting bolts while supporting the compressor weight. The compressor weighs approximately 15 pounds.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
5. 5

   Remove compressor from vehicle
   Carefully maneuver the compressor out of its mounting location, being mindful of nearby HV cables and cooling lines. Tilt the compressor as needed to clear the frame rail and motor housing. Set the old compressor upright on a clean work surface.
6. 6

   Drain and measure old compressor oil
   Drain the old compressor completely into a graduated container by removing the drain plug or tilting. Measure the amount of oil recovered. If less than 50ml or more than 200ml was in the old compressor, inspect the system for oil migration issues or leaks.
7. 7

   Prepare new compressor
   Remove shipping caps from new compressor ports. Drain any shipping oil from the new compressor. Using a refrigerant oil injector, add the appropriate amount of POE oil: use the same quantity that was drained from the old compressor, or 150ml if old compressor oil measurement was unavailable. Rotate the compressor shaft by hand several times to distribute oil internally.
8. 8

   Install new O-rings on AC lines
   Inspect AC line fitting seats for damage or debris. Install new O-rings onto both the suction and discharge line fittings. Lightly coat the O-rings with clean POE oil to aid installation and prevent tearing. Do not use petroleum-based lubricants.
9. 9

   Position and mount new compressor
   Carefully maneuver the new compressor into position on the mounting bracket, ensuring HV cables and other components are not pinched. Align all three mounting holes. Start all mounting bolts by hand to ensure proper thread engagement before tightening.
   Torque spec

   AC Compressor Mounting Bolts25 Nm (18 lb-ft)
10. 10

    Torque compressor mounting bolts
    Using a calibrated torque wrench, tighten the compressor mounting bolts in a star pattern to 25.0 Nm (18 lb-ft). Verify all bolts are fully seated and torqued to specification.
    Torque spec

    AC Compressor Mounting Bolts25 Nm (18 lb-ft)
11. 11

    Connect AC refrigerant lines
    Remove caps from compressor ports. Carefully thread the suction and discharge line fittings onto the compressor by hand, ensuring O-rings remain properly seated. Tighten fittings using a torque wrench to 20.0 Nm (15 lb-ft). Do not over-torque as this can damage O-rings and cause leaks.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
12. 12

    Reconnect electrical connections
    Reconnect the 12V control connector to the compressor, ensuring it clicks fully into place. Then carefully align and install the HV connector, pushing firmly until it fully seats. Slide the orange safety latch back into the locked position. Verify the latch is fully engaged.
13. 13

    Evacuate and recharge AC system
    Connect vacuum pump to service ports and evacuate the system to 500 microns or lower for at least 45 minutes. Monitor for vacuum decay to verify system integrity. If vacuum holds, recharge system with the exact amount of R-1234yf recovered earlier (typically 1.8-2.2 lbs for EDV 500). Add any additional refrigerant to meet OEM specifications per the underhood label.
14. 14

    Reinstall HV service disconnect and restore power
    Reinstall the HV service disconnect under the rear cargo area. Reconnect the 12V auxiliary battery. Follow Rivian's power-up procedure to re-energize the HV system. Monitor the instrument cluster for any fault codes during system initialization.

Reassembly

1. Reinstall all lower front fascia panels and secure all fasteners
2. Verify all tools and parts have been removed from the motor compartment
3. Check that HV cables are properly routed and secured with OEM clips
4. Ensure no refrigerant lines are kinked or making contact with sharp edges

Verification

• Start the vehicle and turn AC system to maximum cooling
• Verify compressor engages and operates quietly without unusual vibration or noise
• Check that cold air is produced at all vents within 2-3 minutes
• Use leak detector to check all AC line fittings and compressor seals for refrigerant leaks
• Monitor AC system pressures: low side should be 30-40 PSI, high side 200-250 PSI at idle (ambient temp dependent)
• Use Rivian diagnostic software to verify no fault codes are present in climate control system
• Check HV system insulation resistance is within specification (typically >500 megohms)
• Verify compressor current draw is within normal range (typically 5-15A depending on load)
• Test drive vehicle and confirm AC performance is normal under various load conditions

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