This procedure covers the removal and replacement of the AC hose assembly on a 2025 Rivian EDV 500, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM Rivian specification
• AC hose O-rings × 1 — Use OEM Rivian specification
• R-1234yf refrigerant × 1 — As required by system capacity
• PAG oil for R-1234yf systems × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disable the high-voltage system following Rivian service procedures: Power off vehicle, remove 12V auxiliary battery negative terminal, wait 5 minutes
3. Allow AC system to stabilize to ambient temperature (minimum 30 minutes after last operation)
4. Connect AC recovery machine and recover all refrigerant from the system according to EPA regulations
5. Document the amount of refrigerant and oil recovered for recharge reference
6. If equipped, remove underbody panels or wheel well liners as needed to access AC hose routing
7. Take photos of hose routing and connections for reference during reassembly

Procedure

1. 1

   Verify system is depressurized
   Connect AC manifold gauges to the service ports. Verify both high and low side pressures read zero PSI. If any pressure remains, repeat refrigerant recovery process. Document baseline readings.
2. 2

   Access the AC hose assembly
   Depending on which hose segment is being replaced, remove necessary components for access. This may include: front fascia clips, frunk liner panels, or driver side wheel well liner. The EDV 500 routes AC hoses along the driver side from the compressor (mounted near front motor) to the condenser and HVAC unit.
3. 3

   Disconnect electrical connectors
   If the hose assembly includes pressure sensors or temperature sensors, disconnect the electrical connectors. Press the locking tab and pull the connector straight off. Mark or tag each connector for correct reassembly.
4. 4

   Remove hose mounting brackets
   Locate and remove all mounting brackets and clips securing the AC hose assembly to the vehicle body or frame. The EDV 500 typically uses plastic push clips and bolt-secured brackets. Keep all hardware organized by location.
5. 5

   Disconnect hose at compressor
   Using appropriate line wrenches, disconnect the AC hose from the compressor. Hold the compressor fitting stationary with one wrench while loosening the hose nut with another to prevent component damage. Remove and discard the O-rings. Cap the compressor ports immediately to prevent contamination.
6. 6

   Disconnect hose at condenser or HVAC unit
   Using line wrenches, disconnect the opposite end of the hose assembly from the condenser or HVAC unit connection point. Remove and discard O-rings. Cap all open ports immediately with clean plugs to prevent moisture and debris entry.
7. 7

   Remove hose assembly from vehicle
   Carefully route the old AC hose assembly out of the vehicle, noting the exact path through frame channels, around electrical harnesses, and past other components. Inspect the routing path for any sharp edges or wear points that may have damaged the old hose.
8. 8

   Prepare new hose assembly
   Remove the new AC hose assembly from packaging. Verify part number matches vehicle specifications. Inspect all fittings and O-ring sealing surfaces for damage or debris. Install new O-rings on all fittings and lubricate with appropriate PAG oil compatible with R-1234yf refrigerant.
9. 9

   Install new hose assembly
   Route the new AC hose assembly through the vehicle following the exact path documented during removal. Ensure the hose does not contact sharp edges, hot surfaces, or moving components. Maintain proper clearance from high-voltage cables and battery thermal management lines.
10. 10

    Connect hose to compressor
    Remove the protective cap from the compressor port. Verify the new lubricated O-ring is properly seated in the hose fitting. Thread the connection by hand until finger-tight, then use line wrenches to tighten. Hold the compressor fitting stationary while tightening the hose nut. Tighten to manufacturer specification (torque values not available in database - use OEM specification).
11. 11

    Connect hose to condenser or HVAC unit
    Remove protective cap from the condenser or HVAC unit port. Verify new lubricated O-ring is properly seated. Hand-thread the connection, then tighten with line wrenches while holding the component fitting stationary. Tighten to manufacturer specification (torque values not available in database - use OEM specification).
12. 12

    Install mounting brackets and clips
    Reinstall all mounting brackets and clips in their original positions. Ensure the hose is properly supported along its entire length without excessive tension or compression. Verify adequate clearance from all moving parts and heat sources.
13. 13

    Reconnect electrical connectors
    Reconnect any pressure sensor or temperature sensor connectors removed earlier. Ensure each connector locks securely with an audible click. Verify correct connector orientation and that no pins are bent.
14. 14

    Evacuate the AC system
    Connect AC vacuum pump to the service ports. Evacuate the system to 29+ inches of mercury (Hg) vacuum. Maintain vacuum for minimum 45 minutes to remove all moisture and air. Monitor for vacuum decay which would indicate a leak.
15. 15

    Recharge the AC system
    After successful vacuum hold test, recharge the system with the correct amount of R-1234yf refrigerant as documented during recovery (typically verified against system capacity label). Add appropriate amount of PAG oil if significant oil was lost during hose removal. Use AC machine to precisely meter refrigerant charge.

Reassembly

1. Reinstall all underbody panels, wheel well liners, and trim pieces removed during access
2. Reconnect the 12V auxiliary battery negative terminal
3. Re-enable the high-voltage system following Rivian service procedures
4. Torque all fasteners to specification using proper sequence

Verification

• Start the vehicle and enable the AC system to maximum cooling
• Monitor AC manifold gauges for proper system pressures (low side: 25-45 PSI, high side: 200-350 PSI depending on ambient temperature)
• Verify both AC lines become cold at the HVAC unit and warm at the compressor discharge
• Check all connections with electronic leak detector or UV dye method for any refrigerant leaks
• Verify cabin temperature reaches expected cooling performance within 5 minutes
• Check that no error codes are present in the vehicle HVAC system using diagnostic tool
• Inspect all hose routing for proper clearance and secure mounting
• Test drive vehicle and verify AC performance remains consistent under load

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