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

Warnings

Tools required

Parts

• AC condenser assembly × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM R-1234yf compatible
• R-1234yf refrigerant × 1 — Use OEM specification
• PAG oil for R-1234yf system × 1 — Use OEM specification
• Front fascia clips (if broken) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
3. Verify high voltage system is deactivated per Rivian service procedures
4. Connect R-1234yf recovery machine and fully recover refrigerant from AC system, documenting amount removed
5. Allow system to equalize to atmospheric pressure for 10 minutes after recovery
6. Document pre-service refrigerant charge amount and system pressures for reference

Procedure

1. 1

   Remove front fascia lower section
   Remove the plastic rivets and fasteners securing the lower front fascia. There are 8 push-pin fasteners along the bottom edge and 4 additional 8mm bolts behind the grille opening. Carefully pull the lower fascia forward to disengage the upper clips, supporting it to prevent stress on the material. Set aside in a protected area.
2. 2

   Access condenser mounting area
   With the lower fascia removed, locate the AC condenser mounted ahead of the electric motor cooling radiator. Remove the upper grille panel by releasing 6 clip fasteners. This provides clear access to the condenser and refrigerant lines.
3. 3

   Disconnect AC line at condenser inlet
   Using a flare nut wrench, carefully loosen the AC line fitting at the condenser inlet (top connection). Support the condenser to prevent stress while loosening. Once loosened by hand, remove the fitting completely and immediately cap both the line and condenser port to prevent moisture and debris entry. Remove and discard the old O-rings.
   ⚠Even after recovery, residual refrigerant may be present. Work in a well-ventilated area.
   Torque spec

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

   Disconnect AC line at condenser outlet
   Using a flare nut wrench, loosen the AC line fitting at the condenser outlet (bottom connection). Support the condenser while loosening to prevent damage. Remove the fitting completely and cap both the line and condenser port. Remove and discard the old O-rings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove condenser mounting bolts
   Locate the four condenser mounting bolts (two on each side bracket). Using a 10mm socket, remove all four mounting bolts. Support the condenser during removal of the final bolt to prevent it from falling.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
6. 6

   Remove condenser assembly
   Carefully lift the condenser upward and forward to clear the mounting brackets. Angle the condenser as needed to navigate around the radiator support and cooling fan assembly. Be careful not to damage the radiator fins during removal. Inspect the old condenser for signs of damage or debris that may have caused failure.
7. 7

   Inspect and clean mounting area
   Inspect the condenser mounting brackets for damage or corrosion. Check the radiator behind where the condenser was mounted for any debris or damage. Clean the mounting area with compressed air to remove any leaves, dirt, or debris. Verify mounting bolt holes are clean and threads are in good condition.
8. 8

   Prepare new condenser
   Remove the new condenser from packaging. Remove the protective caps from the inlet and outlet ports. Add the appropriate amount of PAG oil specified by Rivian to the new condenser (typically 1-2 oz unless otherwise specified). Verify the new condenser mounting bracket locations match the old unit.
9. 9

   Install new condenser
   Carefully position the new condenser into place, angling it down and into position behind the front fascia opening. Align the condenser mounting brackets with the holes in the vehicle support structure. Hand-start all four mounting bolts before tightening any.
10. 10

    Torque condenser mounting bolts
    Using a torque wrench and 10mm socket, tighten all four condenser mounting bolts in a cross pattern to ensure even seating. Torque to specification. Verify the condenser is securely mounted and does not move when gently pushed.
    Torque spec

    Condenser Mounting Bolts12 Nm (9 lb-ft)
11. 11

    Install new O-rings and connect inlet line
    Install new R-1234yf compatible O-rings on the condenser inlet port, lightly lubricating with PAG oil. Remove the cap from the AC line and verify the fitting is clean. Hand-thread the inlet line fitting onto the condenser to ensure proper alignment, then tighten using a flare nut wrench and torque wrench to specification.
    ⚠Cross-threading can damage expensive AC components. Always hand-start fittings first.
    Torque spec

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

    Install new O-rings and connect outlet line
    Install new R-1234yf compatible O-rings on the condenser outlet port, lightly lubricating with PAG oil. Remove the cap from the AC line and verify the fitting is clean. Hand-thread the outlet line fitting onto the condenser, then tighten using a flare nut wrench and torque wrench to specification.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
13. 13

    Reinstall grille and fascia components
    Reinstall the upper grille panel, ensuring all 6 clips fully engage. Position the lower front fascia and align the upper clips first, then press into place. Install all push-pin fasteners along the bottom edge and the four 8mm bolts behind the grille. Verify all panels are securely attached with even gaps.
14. 14

    Evacuate and recharge AC system
    Connect the R-1234yf recovery/recharge machine to the vehicle service ports. Evacuate the system to at least 29 inches of mercury for a minimum of 30 minutes to remove all air and moisture. Monitor for vacuum hold - system should hold vacuum for 10 minutes without pressure rise. If vacuum holds, recharge with the documented amount of R-1234yf refrigerant plus any additional for the new condenser as specified by Rivian service information.
    ℹ️Failure to properly evacuate will result in poor AC performance and potential compressor damage from moisture.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Clear any DTCs related to high voltage system disconnection using Rivian diagnostic software
3. Verify all front fascia panels are properly aligned and secured

Verification

• Start vehicle and activate AC system to maximum cooling
• Verify compressor engages and system pressures are within specification (typically 25-35 psi low side, 180-250 psi high side at ambient temperature)
• Check all AC line connections for leaks using UV dye and leak detector or electronic leak detector
• Verify vent temperature reaches 40-45°F within 5 minutes of operation
• Inspect front fascia for proper fitment and ensure no rattles or loose panels
• Test drive vehicle and verify AC performance under load conditions
• Document final refrigerant charge amount in service records

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