Air Line

This procedure covers the replacement or repair of pneumatic air supply lines in the 2022 Rivian EDV 500 delivery van, including compressed air system components used for auxiliary systems.

Warnings

Tools required

Parts

• Air line assembly × 1 — Use OEM specification
• Push-to-connect fittings × 4 — Use OEM specification
• Air line mounting clips × 6 — Use OEM specification
• O-rings for air fittings × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels for additional safety
3. Disconnect the 12V low voltage battery negative terminal and wait 2 minutes
4. Access the air compressor system located in the rear cargo area driver side
5. Locate the air system pressure relief valve near the compressor tank
6. Slowly open the pressure relief valve to depressurize the entire air system until gauge reads 0 PSI
7. Identify the specific air line requiring service and trace its routing from compressor to destination
8. Remove necessary interior trim panels or cargo area panels to access air line routing
9. Take photos of air line routing and connection points for reference during reinstallation

Procedure

1. 1

   Remove cargo area access panels
   Remove the driver side rear cargo area trim panels to access the air compressor and main air line distribution point. Use trim removal tools to carefully release the panel clips starting from the bottom edge and working upward. Disconnect any electrical connectors for lighting or sensors attached to the panels. Set panels aside in a clean area to prevent damage.
2. 2

   Verify system depressurization
   Double-check that the air system is fully depressurized by attempting to activate any pneumatic functions from the driver controls. Confirm the pressure gauge at the compressor tank reads 0 PSI. If any residual pressure is present, reopen the relief valve until completely depressurized.
3. 3

   Disconnect air line at compressor end
   Locate the damaged air line connection at the compressor manifold or distribution block. Press the collar of the push-to-connect fitting inward while pulling the air line straight out. If the fitting is corroded or damaged, use the appropriate air line disconnect tool. Inspect the fitting for damage and replace if the O-ring is worn or the collar does not move freely.
4. 4

   Release air line mounting clips
   Follow the air line routing along the frame rail or body structure. Release each mounting clip by squeezing the tabs or rotating the clip mechanism as applicable. For the EDV 500, air lines are typically secured every 18-24 inches along their run. Count and note the position of each clip for reinstallation.
5. 5

   Disconnect air line at destination component
   Locate the opposite end of the air line at the pneumatic actuator, suspension component, or other destination. Press the collar of the push-to-connect fitting and remove the air line. If accessing door actuator lines, you may need to remove the door trim panel or access panel. Inspect this fitting as well for damage.
6. 6

   Remove damaged air line from vehicle
   Carefully extract the entire air line from the vehicle, noting its routing path through any grommets, brackets, or body channels. Check for any pinch points or sharp edges that may have caused the original damage. If routing through the chassis, ensure no burrs or sharp edges remain that could damage the new line.
7. 7

   Prepare new air line for installation
   Compare the new air line to the removed line to verify correct length and fitting configuration. If cutting air line to length, use a sharp tubing cutter to ensure a clean, square cut. Deburr the cut end with a deburring tool or fine file. Ensure the line end is smooth and free of debris that could damage O-rings during installation.
8. 8

   Install new mounting clips on air line
   Position new mounting clips on the replacement air line at the locations noted during removal. Clips should be snug but able to slide slightly for final positioning. Do not install clips at the exact ends of the line to allow for insertion into fittings.
9. 9

   Route new air line through vehicle
   Beginning at the compressor end, route the new air line through the same path as the original. Feed the line through any grommets, behind brackets, and along frame rails as required. Ensure the line does not contact any sharp edges, hot components, or moving parts. Maintain adequate clearance from the driveshaft, suspension components, and exhaust routing if applicable.
10. 10

    Connect air line at destination component
    Insert the destination end of the new air line into the push-to-connect fitting. Push the line firmly until it bottoms out in the fitting, then pull back gently to verify it is locked in place. The line should not pull free with moderate force. Ensure the line is inserted past the O-ring seal at least 15-20mm.
11. 11

    Connect air line at compressor end
    Insert the compressor end of the new air line into the manifold or distribution block fitting using the same technique. Push firmly until seated, then verify the connection is secure by pulling back. Ensure the line is routed with a gentle curve and no kinks near the connection point.
12. 12

    Secure mounting clips
    Working along the length of the new air line, position each mounting clip in its designated bracket or mounting point on the frame or body. Press or rotate each clip into the locked position. Verify the air line has no excessive slack or tight spots between mounting points. The line should follow its intended path without stress or sharp bends.
13. 13

    Pressurize and test system
    Reconnect the 12V low voltage battery. Close the air system pressure relief valve. Start the vehicle and allow the air compressor to build system pressure to specification (typically 120-150 PSI for commercial vehicle pneumatic systems). Monitor the pressure gauge and listen for any air leaks along the new line. Apply soapy water solution to all connections and look for bubbles indicating leaks.

Reassembly

1. Reinstall all cargo area trim panels and interior panels in reverse order of removal
2. Reconnect any electrical connectors for lighting or sensors
3. Verify all trim panel clips are fully seated and panels are secure
4. Clean work area and remove any tools or parts from the vehicle

Verification

• Verify air system reaches and maintains proper operating pressure without leaks
• Test all pneumatic functions supplied by the replaced air line (door actuators, suspension controls, etc.)
• Perform a visual inspection of the entire air line routing to confirm proper clearance from moving parts
• Drive the vehicle and listen for any air leaks or unusual sounds from the pneumatic system
• Recheck all connections after 50-100 miles of operation and verify system pressure remains stable

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