This procedure covers the removal and replacement of the AC evaporator core in the 2025 Rivian EDV 500, requiring removal of the HVAC housing and refrigerant recovery.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• HVAC expansion valve × 1 — Replace with evaporator
• Evaporator temperature sensor × 1 — Use OEM specification
• HVAC housing seals and gaskets × 1 — HVAC service seal kit
• AC system O-rings × 1 — R-1234yf compatible O-rings
• R-1234yf refrigerant × 1 — Use OEM specification
• PAG oil for compressor × 1 — R-1234yf compatible
• Cabin air filter × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Access the vehicle service mode through the center display: Settings > Service > Enable Service Mode
3. Disable the high voltage system following Rivian's lockout/tagout procedure
4. Disconnect the 12V auxiliary battery and wait 5 minutes for capacitor discharge
5. Verify zero voltage at high voltage junction box using insulated voltage tester rated for 1000V
6. Recover all R-1234yf refrigerant from the AC system using certified recovery equipment and record amount recovered
7. Move vehicle into climate-controlled workspace if possible to prevent moisture contamination during AC system opening
8. Remove front seats for improved access to lower instrument panel fasteners
9. Document refrigerant capacity and PAG oil amount for recharge procedure

Procedure

1. 1

   Remove instrument panel upper trim and display
   Remove the instrument cluster trim panel by carefully prying at designated release points. Disconnect the ambient light connectors. Remove fasteners securing the center display unit (4 Torx screws). Carefully pull display forward and disconnect all electrical connectors including video, power, and data connections. Support display and set aside in protected area.
2. 2

   Remove lower instrument panel sections
   Remove the driver knee bolster panel by removing 4 screws and releasing clips. Remove passenger lower panel and glove box assembly by removing 6 mounting screws. Disconnect glove box light and any associated connectors. Remove center console lower trim extending toward instrument panel. Access is now available to lower HVAC housing mounting points.
3. 3

   Disconnect AC refrigerant lines
   Locate the AC line connections at the firewall where they enter the HVAC housing. Clean the area around fittings thoroughly. Using appropriate line wrenches, disconnect the liquid line and suction line from the evaporator. Immediately cap all open fittings with R-1234yf compatible plugs to prevent moisture ingress and contamination. Remove the refrigerant line mounting bracket from the firewall (2 bolts).
4. 4

   Disconnect HVAC electrical connections
   Locate and disconnect all electrical connectors from the HVAC assembly including: evaporator temperature sensor, blend door actuators (3 connectors), blower motor connector, and cabin air quality sensor. Press connector release tabs and gently pull connectors straight off. Label each connection with tape or take detailed photos for reference during reinstallation.
5. 5

   Remove steering column covers and drop column
   Remove upper and lower steering column covers (4 screws total). Locate the steering column mounting bolts (4 bolts at column bracket). Support the steering column with a padded stand or assistant. Remove the bolts and carefully lower the steering column to gain clearance for HVAC housing removal. Do not allow column to hang by wiring.
6. 6

   Remove instrument panel support beam
   Locate the instrument panel reinforcement beam mounting bolts (typically 8-10 bolts across the span). Working from one side to the other, remove mounting bolts from the A-pillars, center support bracket, and attachment points to the HVAC housing. Support the beam during removal as it is heavy. Carefully extract the beam through the passenger door opening.
7. 7

   Remove HVAC housing assembly
   Locate all HVAC housing mounting nuts and bolts: 2 upper nuts at firewall studs, 4 bolts securing housing to floor brackets, and 2 side mounting bolts. Remove all fasteners while supporting the housing. Disconnect the fresh air inlet duct from the housing. Carefully work the housing assembly rearward and away from the firewall studs. Maneuver the assembly out through the passenger side opening. This is a large, awkward component requiring care.
8. 8

   Disassemble HVAC housing
   Place the HVAC housing on a clean workbench. Remove the housing cover screws (approximately 12 screws around perimeter). Carefully separate the upper and lower housing halves. Remove the blower motor assembly. Disconnect the expansion valve from the evaporator inlet. Note the orientation and position of all foam seals and air routing baffles for proper reassembly.
9. 9

   Remove evaporator core
   Lift the evaporator core straight up and out of the lower housing section. Remove and discard the old evaporator temperature sensor. Inspect the evaporator case for debris, leaves, or evidence of water leaks. Clean the housing interior with compressed air and approved HVAC cleaner. Check all drain tubes are clear and unobstructed.
10. 10

    Install new evaporator and expansion valve
    Add the specified amount of fresh PAG oil to the new evaporator (typically 2-3 oz - verify with service data). Install the new evaporator temperature sensor into the new evaporator core. Carefully place the new evaporator into the lower housing, ensuring proper seating in the locating features. Install the new expansion valve with new O-rings lightly coated with PAG oil. Ensure all foam seals are properly positioned.
11. 11

    Reassemble HVAC housing
    Reinstall the blower motor assembly. Carefully align the upper and lower housing halves, ensuring all air baffles and seals remain in proper position. Install all housing screws, working in a cross-pattern to ensure even compression of seals. Verify smooth operation of all blend door actuator shafts before proceeding.
12. 12

    Install HVAC housing in vehicle
    With assistance, carefully maneuver the HVAC housing assembly into the vehicle through the passenger opening. Guide the assembly onto the firewall studs and align with all mounting points. Install all mounting fasteners finger-tight first, then torque in sequence: firewall nuts, floor bracket bolts, and side mounting bolts. Reconnect the fresh air inlet duct.
13. 13

    Reconnect refrigerant lines
    Remove caps from evaporator fittings and refrigerant lines. Inspect all O-rings and replace if damaged. Apply a light coat of PAG oil to O-rings. Connect the liquid line and suction line to the evaporator fittings, torquing to specification. Reinstall the line mounting bracket to the firewall. Double-check all connections are properly tightened.
14. 14

    Vacuum and recharge AC system
    Connect AC manifold gauges to the service ports. Pull a vacuum on the AC system for minimum 45 minutes using a vacuum pump. Monitor for vacuum decay - system should hold vacuum indicating no leaks. If vacuum holds, recharge the system with the recorded amount of R-1234yf refrigerant using approved charging equipment. Add any additional PAG oil if required per service specifications.
15. 15

    Reinstall instrument panel components
    Reinstall the instrument panel support beam and torque all mounting bolts. Raise the steering column into position and install column mounting bolts. Reconnect all HVAC electrical connectors: evaporator temperature sensor, blend door actuators, blower motor, and air quality sensor. Reinstall steering column covers, lower instrument panels, glove box assembly, center display, and all trim pieces. Install new cabin air filter. Reinstall front seats.

Reassembly

1. Reinstall components in reverse order of removal, ensuring all electrical connectors are fully seated and locked
2. Verify all instrument panel trim pieces are properly clipped and secured before testing
3. Double-check that all HVAC electrical connections are made before energizing the system

Verification

• Reconnect the 12V auxiliary battery and exit service mode through the vehicle display
• Re-enable the high voltage system following Rivian procedures
• Start the vehicle and allow HVAC system to initialize - verify no warning messages on display
• Test AC operation in MAX AC mode - verify cold air output at all vents within 2-3 minutes
• Check evaporator temperature sensor reading in vehicle diagnostics - should show decreasing temperature when AC is running
• Inspect all AC line connections at firewall for signs of refrigerant leakage using leak detector
• Verify proper operation of all blend doors and air distribution modes
• Test defrost, floor, vent, and bi-level modes for proper air routing
• Check that blower motor operates smoothly at all fan speeds without unusual noise
• Monitor AC system pressures with manifold gauges - should show normal operating pressures per specifications
• Verify no refrigerant odor in cabin and no moisture accumulation on floor carpets
• Test heat pump heating mode if applicable to verify system functionality in both modes

More procedures for this vehicle