AC Hose - Low Side

This procedure covers the removal and replacement of the low-side AC hose on a 2025 Rivian EDV 500 commercial delivery van, including refrigerant recovery, evacuation, and recharge.

Warnings

Tools required

Parts

• AC low-side hose assembly × 1 — Use OEM Rivian specification
• AC line O-ring kit × 1 — Use OEM specification with R-1234yf compatibility
• PAG oil for R-1234yf systems × 1 — Use OEM-specified PAG oil viscosity
• R-1234yf refrigerant × 1 — Approximately 2.5-3.0 lbs total system capacity

Preparation

1. Verify the AC system concern and confirm the low-side hose requires replacement through visual inspection or leak detection
2. Park vehicle on level surface and engage parking brake
3. Disconnect 12-volt battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Verify high-voltage system is disabled through the vehicle service mode menu
5. Document the refrigerant type and verify R-1234yf compatibility of all equipment and parts
6. Ensure AC recovery machine is properly maintained and certified for R-1234yf use
7. Remove front driver-side wheel well liner for access to low-side service port and hose routing (if applicable to EDV 500 configuration)
8. Remove lower front fascia panels as needed for access to condenser and AC line routing

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to the low-side service port located near the accumulator/dryer. Follow machine manufacturer procedures to completely recover all refrigerant from the system. Record the amount of refrigerant and oil recovered for recharge calculations. Ensure recovery is complete by monitoring system pressure reaching atmospheric levels.
2. 2

   Locate and access low-side AC hose
   The low-side hose runs from the evaporator outlet (inside the HVAC module area) to the compressor suction inlet. On the EDV 500, trace the hose routing from the accumulator/dryer assembly forward to the electric compressor. Remove any wire harness clips, cable ties, or brackets securing the hose to the chassis or body. Note the exact routing and position of all mounting points for reinstallation.
3. 3

   Disconnect low-side hose at evaporator end
   Remove the protective cover from the evaporator connection point (typically accessed through the firewall area or under the dashboard depending on EDV configuration). Use the appropriate AC line disconnect tool to release the quick-connect fitting or remove the flare/block fitting bolts. Immediately cap the evaporator port with a clean plug to prevent moisture ingress and contamination.
4. 4

   Disconnect low-side hose at compressor end
   Disconnect the electrical connector from the compressor if needed for clearance. Remove the bolt(s) securing the low-side hose flange or block fitting to the compressor suction port. Carefully withdraw the fitting and immediately cap both the hose end and compressor port to prevent contamination. Inspect the removed connection for metal debris or excessive oil indicating compressor failure.
5. 5

   Remove low-side hose assembly
   Remove all remaining mounting brackets, clips, and grommets securing the hose to the vehicle structure. Note the position of any sound dampening isolators. Carefully remove the complete hose assembly, taking care not to damage surrounding components including high-voltage cables, coolant lines, and brake lines. Inspect the removed hose for damage, wear, or contamination source.
6. 6

   Prepare new low-side hose
   Remove the new AC hose from its sealed packaging only when ready to install. Verify the part number matches the original hose and includes all necessary brackets and fittings. Install new O-rings at all connection points, lubricating them lightly with fresh R-1234yf-compatible PAG oil. Do not remove protective caps until immediately before connection.
7. 7

   Install new low-side hose assembly
   Route the new hose assembly through the vehicle following the exact path of the original, ensuring proper clearance from moving parts, heat sources, and sharp edges. Install all mounting brackets, clips, and grommets in their original positions. Ensure the hose is properly supported and does not have tension, kinks, or contact points that could cause vibration or wear.
8. 8

   Connect hose at compressor suction port
   Remove the cap from the compressor port and new hose end. Inspect O-rings for proper seating and light oil coating. Install the hose fitting to the compressor suction port and hand-tighten the connection. Torque the flange bolts or block fitting to specification per Rivian service information (typically 15-18 ft-lbs for AC fittings, verify with OEM documentation as no torque specs are available in database).
9. 9

   Connect hose at evaporator end
   Remove the cap from the evaporator port and hose end. For quick-connect fittings, ensure the O-ring is properly seated and push the connection together until it clicks into place, then verify it is locked. For flare or block fittings, hand-tighten first, then torque to specification per Rivian service documentation. Verify the connection is fully seated and secure.
10. 10

    Add replacement refrigerant oil
    Calculate the amount of PAG oil to add based on the amount recovered and the hose volume (typically 1-2 oz for hose replacement). Use only the Rivian-specified PAG oil viscosity for R-1234yf systems. Inject the measured oil into the system through the low-side service port using an oil injector tool before evacuating.
11. 11

    Evacuate AC system
    Connect the AC machine to both service ports. Evacuate the system to a deep vacuum (minimum 29 inches Hg) for at least 30-45 minutes. Monitor for vacuum decay - the system should hold vacuum with minimal loss (less than 1 inch Hg over 10 minutes) indicating no leaks. If vacuum does not hold, locate and repair the leak before proceeding.
12. 12

    Recharge AC system with R-1234yf
    Using the AC machine, recharge the system with the amount of R-1234yf refrigerant documented during recovery (typically 2.5-3.0 lbs total system capacity for EDV 500). Follow the machine's automatic charging procedure or manually charge through the low-side port with the engine running and AC on maximum cooling. Monitor pressures to ensure proper charge level.
13. 13

    Perform electronic leak detection
    Using an electronic leak detector certified for R-1234yf, carefully check all connection points including both ends of the new low-side hose, the service ports, and surrounding connections. Pay particular attention to the areas that were disturbed during repair. Any detected leaks must be corrected before completing the repair.

Reassembly

1. Reinstall all access panels, wheel well liners, and front fascia components removed during disassembly
2. Reconnect any wire harness clips or cable ties that were removed for hose access
3. Reinstall the driver-side front wheel if removed (torque lug nuts per Rivian specification)
4. Reconnect the 12-volt battery negative terminal
5. Clear any diagnostic trouble codes related to AC system service mode or battery disconnect using Rivian diagnostic software

Verification

• Start the vehicle and verify the high-voltage system initializes properly with no new fault codes
• Set the climate control to maximum cooling and monitor system operation for at least 10 minutes
• Verify AC system pressures are within normal range: low-side approximately 25-45 psi and high-side 150-250 psi at idle with ambient temperature around 75°F (pressures vary with temperature)
• Check that the vent temperature reaches appropriate cooling levels (typically 40-50°F at full cold setting)
• Verify no unusual noises from the compressor or hose routing areas during operation
• Perform a final leak check at all connection points with the system running and at full operating pressure
• Verify proper compressor cycling and that the HVAC system responds correctly to all climate control inputs
• Document the refrigerant charge amount and service date in vehicle records per EPA requirements

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