AC Hose - High Side

This procedure involves replacing the high-side AC hose on a 2025 Rivian EDV 500, requiring refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• High side AC hose assembly × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• AC system oil (POE oil for R-1234yf) × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As required per system capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
3. Verify AC system is at ambient temperature (not recently operated)
4. Position drip pans under potential refrigerant release points
5. Ensure AC recovery machine is certified for R-1234yf and properly calibrated
6. Have replacement O-rings and proper POE oil ready before opening system

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to low and high side service ports. Follow machine instructions to completely recover all refrigerant from the system. Record the amount of refrigerant and oil recovered for recharge reference. Verify system reaches full vacuum indicating complete recovery.
2. 2

   Access high side hose routing
   Remove front underbody panel fasteners to access AC lines from below. The high side hose routes from the compressor (located near the front drive unit) to the condenser behind the front bumper. Remove any cable ties or brackets securing the hose along its routing path. On the EDV 500, you may need to remove the driver side front wheel and inner fender liner for full access.
3. 3

   Disconnect high side hose at compressor
   Locate the high side hose connection at the compressor discharge port. Use two wrenches to prevent component rotation: hold the compressor fitting stationary with one wrench while loosening the hose connection nut with another. Once loosened, remove the connection and immediately cap both openings to prevent moisture and debris entry. Remove and discard the O-rings from the connection.
4. 4

   Disconnect high side hose at condenser
   Trace the high side hose to its connection at the condenser inlet. This connection is typically accessed from the front of the vehicle. Use the two-wrench method to loosen and disconnect the hose from the condenser. Cap both openings immediately. Remove and discard the O-rings. Note the routing and any support bracket positions for reinstallation.
5. 5

   Remove mounting brackets and extract hose
   Release any remaining mounting brackets or clips securing the high side hose to the vehicle chassis or other components. Carefully extract the hose from its routing path, taking care not to damage nearby wiring harnesses, brake lines, or other AC components. Inspect the mounting locations for damage or corrosion.
6. 6

   Inspect and prepare new hose
   Inspect the new high side hose for any shipping damage or defects. Verify correct part number and routing configuration matches the original. Coat new O-rings with appropriate POE oil (compatible with R-1234yf). Install new O-rings onto both ends of the new hose assembly, ensuring they seat properly in their grooves.
7. 7

   Route new high side hose
   Route the new high side hose along the original path, ensuring it does not contact sharp edges, moving components, or exhaust system parts. The hose should have adequate clearance from all components throughout its full range of suspension and steering motion. Temporarily secure with mounting brackets.
8. 8

   Connect hose at condenser
   Remove caps from condenser inlet and new hose. Verify O-rings are properly positioned and lubricated. Hand-thread the connection to ensure proper alignment, then use the two-wrench method to tighten the connection. Tighten securely but do not over-torque aluminum fittings. Without torque specifications, tighten firmly until resistance is felt, then an additional 1/6 turn.
9. 9

   Connect hose at compressor
   Remove caps from compressor discharge port and hose end. Verify O-rings are in place and properly lubricated. Hand-thread the connection carefully to avoid cross-threading. Use the two-wrench method to tighten the connection, holding the compressor fitting stationary. Tighten securely but avoid over-torque on aluminum threads.
10. 10

    Secure hose routing and brackets
    Install all mounting brackets, clips, and cable ties to secure the high side hose in its proper position. Ensure the hose does not contact any moving parts, sharp edges, or heat sources. Verify adequate clearance during suspension compression and steering lock-to-lock movement. Double-check all connections are tight.
11. 11

    Evacuate AC system
    Connect vacuum pump to AC system service ports. Evacuate the system to at least 500 microns and hold for minimum 30 minutes. Monitor vacuum gauge for any rise in pressure that would indicate a leak. System should hold vacuum indicating all connections are sealed. If vacuum does not hold, locate and repair leak before proceeding.
12. 12

    Recharge AC system
    Using the R-1234yf recharge machine, add the appropriate amount of refrigerant and POE oil to the system based on recovered quantities and manufacturer specifications. The system should receive the original amount of refrigerant plus any oil lost with the old hose. Follow recharge machine instructions for proper procedure. Add UV dye if desired for future leak detection.
13. 13

    Reassemble vehicle components
    Reinstall inner fender liner, front wheel (if removed), and underbody panels. Torque wheel lug nuts to specification. Ensure all fasteners are properly secured. Reconnect 12V battery negative terminal.

Reassembly

1. Verify all AC line connections are tight and properly secured
2. Ensure all mounting brackets and cable ties are installed
3. Confirm proper hose routing with adequate clearance from all moving parts
4. Reinstall all access panels, fender liners, and underbody covers
5. Verify no tools or materials are left in engine compartment or undercarriage

Verification

• Start vehicle and allow AC system to run for 10 minutes
• Verify cold air output from cabin vents (vent temperature should reach approximately 40-45°F)
• Use refrigerant leak detector to check all connections for leaks
• Inspect all hose connections visually for refrigerant oil seepage
• Verify compressor cycles on and off normally with AC engaged
• Check AC system pressures with manifold gauges (if equipped) to verify proper charge
• Monitor system operation during test drive with various AC settings
• Verify no unusual noises from AC compressor or hose vibration
• Confirm adequate clearance of hose during suspension and steering movement

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