This procedure guides you through the replacement of the AC pressure sensor on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, including refrigerant recovery and recharge.

Warnings

Tools required

Parts

• AC pressure sensor × 1 — Use OEM Rivian specification
• O-ring seal for pressure sensor × 1 — Usually included with sensor
• R-1234yf refrigerant × 1 — Use correct type for electric vehicle
• PAG oil for electric compressor × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery and wait 5 minutes for system capacitors to discharge
3. Verify high voltage system is disabled per Rivian service procedures
4. Allow HVAC system to cool to ambient temperature if recently operated
5. Connect AC recovery machine to service ports and verify machine is ready
6. Document pre-service AC system pressures if system is still charged
7. Remove front undershield or wheel well liner if necessary for access to condenser area

Procedure

1. 1

   Recover refrigerant from AC system
   Connect the AC recovery machine to both low and high-pressure service ports. Follow machine instructions to completely recover all R-1234yf refrigerant from the system. Record the amount of refrigerant recovered for recharge reference. Ensure recovery is complete before proceeding.
2. 2

   Locate AC pressure sensor
   The AC pressure sensor is mounted on the high-pressure refrigerant line near the condenser assembly in the front compartment. It will have an electrical connector and is threaded directly into the refrigerant line. Identify the sensor and verify part number if visible.
3. 3

   Disconnect electrical connector
   Press the locking tab on the electrical connector and carefully pull straight back to disconnect the wiring harness from the AC pressure sensor. Inspect connector pins for corrosion or damage. Do not pull on wires.
4. 4

   Remove old AC pressure sensor
   Using a 7mm wrench or socket, carefully unthread the AC pressure sensor from the refrigerant line fitting. Turn counterclockwise to remove. Some residual refrigerant or oil may escape during removal. Keep the opening covered to prevent contamination.
5. 5

   Inspect O-ring and fitting
   Examine the old O-ring seal from the sensor for damage, cracking, or deformation. Inspect the threads and sealing surface on the refrigerant line fitting for damage, debris, or corrosion. Clean threads if necessary using a lint-free cloth. Do not allow debris to enter the system.
6. 6

   Prepare new AC pressure sensor
   Remove the new AC pressure sensor from packaging. Verify the correct part number matches the old sensor. Install the new O-ring seal onto the sensor if not pre-installed. Apply a thin film of clean PAG oil to the O-ring to aid installation and sealing.
7. 7

   Install new AC pressure sensor
   Thread the new AC pressure sensor into the refrigerant line fitting by hand, turning clockwise. Ensure the sensor threads smoothly and is not cross-threaded. Hand-tighten until the O-ring makes contact with the sealing surface. Then use a torque wrench to tighten to manufacturer specification (typically 10-15 ft-lb, but verify with Rivian service information as no specific torque is provided in database).
8. 8

   Reconnect electrical connector
   Align the electrical connector with the sensor pins and push firmly until the locking tab clicks into place. Gently tug on the connector to verify it is securely locked. Ensure the wiring harness is properly routed and not in contact with sharp edges or heat sources.
9. 9

   Vacuum test AC system
   Connect the vacuum pump or AC machine vacuum function to the service ports. Evacuate the system to at least 29 inches of mercury vacuum. Hold vacuum for at least 30 minutes. Monitor for pressure rise which would indicate a leak at the sensor or elsewhere in the system.
10. 10

    Recharge AC system with refrigerant
    Using the AC machine, recharge the system with the amount of R-1234yf refrigerant recovered (or per Rivian specifications if significantly different). Add the appropriate amount of PAG oil if required by service procedures. Monitor pressures during charging to ensure proper fill.
11. 11

    Perform leak test
    Use an electronic leak detector approved for R-1234yf refrigerant. Carefully check the new AC pressure sensor fitting, surrounding connections, and service ports for any refrigerant leaks. Pay special attention to the sensor O-ring seal area.
12. 12

    Reinstall access panels
    Reinstall any undershields, wheel well liners, or panels that were removed for access. Ensure all fasteners are properly secured and panels are seated correctly.
13. 13

    Reconnect 12V battery
    Reconnect the 12V auxiliary battery. The vehicle may require a brief initialization period. Clear any HVAC-related diagnostic trouble codes that were set during the repair using the Rivian diagnostic system.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all access panels and shields are properly reinstalled
3. Double-check that no tools or parts were left in the engine compartment
4. Confirm AC system is fully charged to specification

Verification

• Start the vehicle and allow HVAC system to initialize
• Set climate control to maximum cooling and monitor for proper operation
• Check that AC compressor engages and disengages properly
• Verify AC pressure readings are within normal range using diagnostic system (typically 30-50 psi low side, 150-300 psi high side depending on ambient temperature)
• Monitor AC pressure sensor signal voltage or pressure reading using Rivian diagnostic tool to confirm proper sensor operation
• Verify no refrigerant odor is present and perform final visual leak inspection
• Test drive vehicle and confirm climate control functions properly under various conditions
• Verify no HVAC-related diagnostic trouble codes are present

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