Air Suspension Height Sensor

Replace the air suspension height sensor on a 2023 Chevrolet Bolt EUV to restore proper ride height adjustment and suspension system functionality.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM specification
• Sensor mounting hardware kit × 1 — Check if included with sensor

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open hood and disconnect 12V battery negative terminal
4. If equipped with air suspension, access suspension control module and disable system per manufacturer instructions
5. Allow system to vent air pressure completely (if applicable)
6. Loosen wheel lug nuts while vehicle is on ground
7. Raise vehicle with floor jack at designated lift point
8. Support vehicle securely on jack stands rated for vehicle weight
9. Remove wheel completely

Procedure

1. 1

   Remove wheel and locate height sensor
   With the wheel removed, locate the air suspension height sensor mounted to the lower control arm or suspension component. The sensor will have a link arm connected to the chassis or opposite suspension component and an electrical connector. Clean the area around the sensor mounting points with a wire brush if corrosion is present.
2. 2

   Disconnect sensor electrical connector
   Locate the electrical connector on the height sensor. Press the release tab or locking mechanism and carefully disconnect the wiring harness from the sensor. Inspect connector pins for corrosion or damage. If connector is difficult to release, use an electrical connector release tool to avoid breaking tabs.
3. 3

   Disconnect sensor link arm
   The height sensor has a link arm that connects to a ball joint or clip attachment point on the suspension. Depending on design, this may be a ball socket that pulls off, a clip that releases, or a small bolt. Carefully release the link arm from its attachment point on the control arm or chassis. Note the orientation and position for installation of new sensor.
4. 4

   Remove sensor mounting fasteners
   Remove the mounting bolts or screws securing the height sensor to its bracket on the suspension component. Most sensors use 2-3 mounting bolts. If mounting bolts are corroded, apply penetrating oil and allow to soak for several minutes before removal. Keep mounting hardware if reusable.
5. 5

   Remove old height sensor
   Carefully remove the height sensor assembly from the vehicle. Inspect the mounting bracket for damage, corrosion, or bent components. Clean the mounting surface thoroughly with a wire brush to ensure proper seating of the new sensor.
6. 6

   Prepare new height sensor
   Remove new height sensor from packaging and verify it matches the old sensor in appearance and connector type. Check that the link arm length and mounting hole positions are identical. If the sensor has an adjustable link arm, set it to the same length as the old sensor before installation.
7. 7

   Install new sensor to mounting bracket
   Position the new height sensor onto the mounting bracket in the same orientation as the original. Install mounting bolts finger-tight first to ensure proper alignment. Once aligned correctly, torque mounting bolts to specification in a cross pattern if multiple bolts are present.
8. 8

   Connect sensor link arm
   Attach the sensor link arm to the suspension component or chassis attachment point. Ensure the ball joint or clip is fully seated and locked in place. The link arm should move freely through its range of motion without binding. Verify the sensor is at approximately mid-range position when vehicle is at normal ride height.
9. 9

   Connect electrical connector
   Plug the wiring harness connector into the new height sensor until you hear or feel a positive click. Gently tug on the connector to verify it is locked in place. Ensure no wires are pinched or routed where they can contact moving suspension components or sharp edges.
10. 10

    Reinstall wheel and lower vehicle
    Reinstall the wheel onto the hub, starting all lug nuts by hand. Tighten lug nuts in a star pattern to seat the wheel properly. Lower the vehicle until the tire just contacts the ground but most weight is still on jack stands. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands.
11. 11

    Reconnect battery and initialize system
    Reconnect the 12V battery negative terminal. If vehicle has air suspension control module, access the system and perform initialization or calibration procedure per manufacturer instructions. This typically involves turning ignition on, cycling the suspension through its range, or using a scan tool to calibrate sensor range.

Reassembly

1. Verify all mounting bolts are torqued to specification
2. Ensure electrical connector is fully seated and locked
3. Check that sensor link arm moves freely without binding
4. Confirm no tools or parts were left in wheel well area
5. Test suspension system operation before driving

Verification

• With ignition on, verify no suspension warning lights are illuminated on instrument cluster
• If equipped with air suspension controls, cycle through ride height settings and verify sensor responds correctly
• Use a scan tool to read height sensor output and verify it changes appropriately when suspension is compressed and extended manually
• Perform a test drive and verify suspension adjusts to proper ride height automatically
• Check for any abnormal suspension noises or warning messages
• Visually inspect sensor installation to ensure link arm has adequate clearance through full suspension travel

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