hvac

AC High Pressure Switch

for 2025 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Advanced

Time

4.0 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure involves replacing the AC high pressure switch on a 2025 Rivian EDV 500, which monitors refrigerant pressure in the air conditioning system and requires partial refrigerant system service.

Warnings

⚠️This vehicle contains high voltage systems exceeding 400 volts. Always verify HV system is disabled before beginning work. Failure to do so may result in severe injury or death.

⚠️R-1234yf refrigerant is mildly flammable. Never use open flames near the AC system. Use only approved recovery equipment in well-ventilated areas.

⚠️AC refrigerant under pressure can cause severe frostbite. Always wear eye protection and insulated gloves when working with AC components.

⚠The AC high pressure switch is located near high voltage components. Maintain awareness of orange HV cable locations at all times.

⚠Rivian EDV uses EV-specific PAG oil. Do not substitute conventional AC compressor oil as it may damage the electric compressor.

Tools required

R-1234yf AC recovery/recharge machineEssential

Torque wrench (ft-lb and in-lb)Essential

7mm, 10mm, 13mm socket setEssential

Insulated gloves (Class 0 or higher)Essential

Digital multimeterEssential

Rivian diagnostic scan toolEssential

Panel removal tool set

UV leak detection kit

Safety glasses with side shieldsEssential

AC line disconnect toolsEssential

Parts

AC High Pressure Switch × 1 — Use OEM Rivian specification
AC system O-rings × 2 — Use OEM specification
R-1234yf refrigerant × 1 — Approximately 1.5 lb
PAG oil for EV AC system × 1 — Use OEM specification

Preparation

Park vehicle on level surface and engage parking brake
Using Rivian diagnostic tool, verify AC system operation and document any fault codes
Access HV disconnect through driver side floor panel by removing cover fasteners
Remove HV service disconnect plug and install safety lock. Wait 5 minutes for capacitor discharge
Verify zero voltage at HV junction box using insulated multimeter rated for 1000V DC minimum
Place HV warning tags on steering wheel and service disconnect area
Connect R-1234yf recovery machine to AC service ports (located in front service compartment)
Recover all refrigerant from the system and record amount recovered for recharge reference
Open hood and remove front undertray panels to access HVAC components

Procedure

1
Access AC high pressure line assembly
Remove the plastic cover over the HVAC module located behind the front bulkhead. This requires removing six push-pin fasteners and two 10mm bolts. Carefully pull the cover forward to disengage the rear clips. The AC high pressure switch is mounted on the high pressure line near the condenser outlet.
2
Disconnect electrical connector
Locate the high pressure switch electrical connector on the AC line. Press the release tab on the connector while pulling straight away from the switch. Do not pull on the wires themselves. Inspect the connector terminals for corrosion or damage.
3
Document and photograph switch location
Before removal, photograph the switch orientation and electrical connector routing. Note the position of any mounting brackets or clips. The switch should be oriented with the connector facing toward the driver side of the vehicle.
4
Remove AC high pressure switch
Using a 13mm wrench, carefully unscrew the high pressure switch from the AC line port. Turn counterclockwise slowly to prevent cross-threading. Once loose, finish removal by hand. Some residual refrigerant oil may drain from the port - this is normal. Immediately cap the open port with a clean plug to prevent moisture and contaminant entry.
5
Inspect AC line port and O-rings
Examine the AC line port threads for damage, corrosion, or metal particles. Check the O-ring sealing surface for scratches or gouges. Remove and discard the old O-ring from the port. Clean the sealing surface with a lint-free cloth and approved AC system cleaner. Do not use petroleum-based solvents.
6
Prepare new high pressure switch
Remove the new AC high pressure switch from packaging. Verify the part number matches the Rivian specification. Install a new lubricated O-ring onto the switch threads, ensuring it seats properly in the O-ring groove. Apply a thin coating of EV-compatible PAG oil to the O-ring.
7
Install new AC high pressure switch
Thread the new high pressure switch into the AC line port by hand, turning clockwise. Ensure the switch threads in smoothly without resistance. Once hand-tight, use a 13mm wrench to tighten the switch. Without a specified torque value, tighten to one full turn past hand-tight, or approximately 15-20 ft-lb. Do not overtighten as this may damage the aluminum port threads.
8
Reconnect electrical connector
Route the electrical connector to the new switch following the original path documented in your photographs. Push the connector onto the switch terminal until you hear and feel a positive click. Gently tug on the connector to verify it is fully seated and locked.
9
Reinstall HVAC module cover
Position the HVAC module plastic cover, engaging the rear clips first. Install the two 10mm bolts and six push-pin fasteners. Ensure all fasteners are fully seated and the cover sits flush against the module.
10
Evacuate AC system
Connect the R-1234yf recovery/recharge machine to the AC service ports. Run a vacuum on the system for a minimum of 45 minutes to remove all air and moisture. The system should hold vacuum at 29+ inches Hg for at least 15 minutes without decay to verify there are no leaks.
11
Recharge AC system
Using the recovery machine, recharge the AC system with the amount of R-1234yf refrigerant recovered earlier, plus any additional oil lost during service (typically 1-2 oz of EV-compatible PAG oil). Follow the machine manufacturer's charging procedure. Do not exceed the system capacity specified on the vehicle AC label.
12
Restore high voltage system
Remove HV warning tags. Reinstall the HV service disconnect plug into the junction box, ensuring it clicks into place. Verify the connector is fully seated. Replace the driver side floor panel cover.
13
Initialize and test AC system
Using the Rivian diagnostic tool, clear any stored AC system fault codes. Start the vehicle and enable the AC system. Monitor the high pressure switch circuit status on the scan tool - it should show normal operation. Allow the AC to run for 5 minutes while monitoring system pressures.

Reassembly

Reinstall front undertray panels and secure all fasteners
Verify all electrical connectors are properly seated and locked
Confirm no tools or parts are left in the engine compartment
Double-check that HV service disconnect is properly reinstalled and secured

Verification

With engine running and AC on MAX, verify cold air from cabin vents (approximately 40-45°F at vents)
Using scan tool, monitor AC high pressure readings - should be 200-275 psi at ambient temperatures above 80°F
Check that AC compressor cycles on and off properly under normal operation
Inspect high pressure switch connection and AC line for any refrigerant leaks using UV dye or electronic leak detector
Verify no AC-related fault codes are present in vehicle system
Test AC operation in various modes (MAX, ECO, defrost) to ensure proper function
Confirm AC high pressure cutout protection activates if system pressure exceeds safe limits (simulate by blocking condenser airflow briefly)

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