AC Recharge

This procedure covers the complete evacuation, vacuum testing, and recharging of the R-1234yf air conditioning system on the 2025 Rivian EDV 500 electric delivery van, including leak detection and system performance verification.

Warnings

Tools required

Parts

• R-1234yf refrigerant × 1 — Use OEM specification
• PAG 46 oil (EV compressor compatible) × 1 — Rivian P/N or equivalent
• AC service port cap seals × 2 — Use OEM specification
• UV leak detection dye (optional) × 1 — R-1234yf compatible

Preparation

1. Park vehicle on level surface and ensure parking brake is engaged
2. Verify vehicle is in Park mode and power is off (not in Ready mode)
3. Connect Rivian Service Toolbox (RST) diagnostic software to vehicle
4. Using RST, place the high voltage system into service mode and verify HV disconnect is complete
5. Wait 5 minutes after HV disconnect for capacitors to discharge
6. Verify high voltage interlock is open using RST diagnostics
7. Allow HVAC system to stabilize to ambient temperature if recently operated
8. Locate AC service ports: low-side port on accumulator near firewall, high-side port on liquid line near condenser
9. Verify adequate ventilation in work area for refrigerant recovery
10. Ensure AC recovery/recharge machine is properly calibrated and contains sufficient clean refrigerant oil

Procedure

1. 1

   Identify and verify refrigerant type
   Connect refrigerant identifier tool to low-side service port. Verify system contains R-1234yf refrigerant only with no contamination. If contamination is detected above 2%, system must be recovered with dedicated contaminated refrigerant equipment and flushed before proceeding. Check vehicle refrigerant capacity label under hood (typical capacity is 1.8-2.1 lbs for EDV 500).
2. 2

   Record baseline system data
   With vehicle still powered off, use RST to record HVAC system data including: last operating pressures, compressor runtime hours, thermal management system status, and any stored fault codes. Note ambient temperature. Visually inspect all accessible AC lines, condenser, and connections for obvious leaks, damage, or oil residue.
3. 3

   Recover existing refrigerant
   Connect R-1234yf recovery machine to both high and low-side service ports. Open both service valves and begin recovery process following machine manufacturer procedures. Recovery is complete when machine indicates no pressure change for 5 minutes and internal tank pressure stabilizes. Record amount of refrigerant recovered. If recovered amount is 30% or more below specification, significant leak is present and must be repaired before recharging.
4. 4

   Add UV dye if performing leak detection
   If system history indicates potential leaks or recovered refrigerant was significantly low, inject manufacturer-specified amount of UV leak detection dye (typically 1 oz) through the low-side port using dye injector tool. Ensure dye is R-1234yf compatible and approved for EV compressor systems.
5. 5

   Evacuate system and perform vacuum test
   Connect vacuum pump to AC machine and begin evacuation of system. Pull vacuum to at least 500 microns (29.9 inches Hg). Maintain deep vacuum for minimum 30 minutes to remove all moisture and air. After 30 minutes, close all valves and monitor vacuum level for 10 minutes. If vacuum rises above 1000 microns, system has a leak and must be repaired. On EDV models, also monitor battery thermal management coolant reservoir for level changes indicating internal heat exchanger leak.
6. 6

   Check compressor oil level and condition
   Measure amount and condition of oil recovered from system. EDV electric compressor requires PAG 46 oil specifically formulated for high voltage EV compressors. If recovered oil appears contaminated, burnt, or contains metal particles, compressor may be failing. Replace oil quantity that was removed plus 1 additional ounce to compensate for oil trapped in system components. Load correct amount of fresh PAG 46 EV-rated oil into recharge machine.
7. 7

   Recharge system with R-1234yf
   Using AC recharge machine in automatic mode, charge system with manufacturer-specified amount of R-1234yf refrigerant (verify exact specification on underhood label, typically 1.9-2.0 lbs for EDV 500). Machine will inject refrigerant into low-side port first, then equalize through high side. Monitor pressures during charging process. Do not exceed 300 PSI on high side during charging.
8. 8

   Exit HV service mode and enable HVAC system
   Using RST software, exit high voltage service mode following proper Rivian procedures. Verify HV system returns to Ready status with no fault codes. Wait for HV contactors to close (indicated in RST). Place vehicle in Ready mode. Do not touch any HV components once system is re-energized.
9. 9

   Perform initial system operation test
   With vehicle in Ready mode, access HVAC controls and set system to MAX AC mode with fan on highest setting and temperature at 60°F. Allow system to run for 2 minutes while monitoring RST for compressor engagement. Verify electric compressor activates (indicated by current draw visible in RST). Check that both low and high-side pressures stabilize within normal range: low-side 25-45 PSI, high-side 150-250 PSI at 70-80°F ambient.
10. 10

    Check system pressures and temperatures
    With system running in MAX AC for 5 minutes at idle, verify operating pressures using manifold gauges: Low side should be 30-40 PSI, high side 180-220 PSI at 75°F ambient (adjust expectations for actual ambient temperature). Measure center vent discharge temperature with thermometer; should reach 40-45°F within 5 minutes. Monitor compressor current draw in RST; should be 8-15 amps under normal load.
11. 11

    Perform electronic leak detection
    With system pressurized and running, use electronic leak detector to check all accessible connections, service ports, compressor electrical connections, condenser, evaporator drain area, and all line connections. Pay special attention to high-pressure line connections near condenser and compressor. If UV dye was added, use UV flashlight in darkened area to check for fluorescent dye traces indicating leaks.
12. 12

    Verify heat pump operation (if applicable)
    Set HVAC system to HEAT mode with temperature at 72°F. Verify system switches to heat pump mode (compressor continues to run but refrigerant flow reverses). Check that warm air is discharged from vents reaching at least 100°F within 3 minutes. Monitor RST to confirm heat pump valve actuation and proper thermal management system integration.
13. 13

    Check thermal management system integration
    Using RST, monitor battery thermal management system coolant temperatures and flow. Verify that HVAC recharge has not affected battery cooling system operation. Check coolant reservoir level in thermal management system (located in front compartment). Top off coolant if needed using EV Battery/Motor Coolant specification. No cross-contamination should occur between AC refrigerant and coolant systems.
14. 14

    Document service and clear adaptations
    Using RST, clear any HVAC-related fault codes that may have set during service. Reset HVAC system adaptations to allow system to relearn operating parameters. Document in RST service records: refrigerant amount added, oil amount added, system pressures, discharge temperatures, and any repairs performed. Update vehicle service history.

Reassembly

1. Install new sealing caps on both high and low-side service ports
2. Secure all AC line clips and protective covers that were moved during service
3. Verify no tools or equipment remain in engine compartment
4. Close hood and restore vehicle to normal operating configuration

Verification

• Perform final 10-minute drive test with AC running in MAX mode; discharge temperature should remain 38-45°F
• Verify no abnormal noises from compressor or refrigerant lines during operation
• Check RST for any new fault codes related to HVAC or thermal management systems
• Confirm static pressures after 1 hour cool-down period: both high and low sides should equalize to 70-90 PSI at 70°F ambient
• Re-check all connection points with leak detector after drive test
• Verify battery thermal management system shows no faults and coolant level is stable
• Document final system pressures, temperatures, and confirm no leaks detected
• Provide customer with service documentation including refrigerant amount, oil added, and next recommended service interval

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