This procedure covers the removal and replacement of air spring/air bag assemblies on the Rivian EDV 500 commercial van's air suspension system.

Warnings

Tools required

Parts

• Air spring/air bag assembly × 1 — Use OEM Rivian specification
• Air line O-rings × 2 — Use OEM specification
• Mounting hardware kit (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock wheels on opposite end of vehicle from repair location
3. Connect Rivian diagnostic tool and enter service mode for air suspension
4. Use diagnostic tool to raise air suspension to maximum height for easier access
5. Disconnect 12V battery negative terminal and wait 5 minutes
6. Raise vehicle on lift or jack and support frame on rated jack stands - do not rely on air suspension
7. Remove wheel and tire assembly at corner being serviced
8. Clean suspension area with wire brush and apply penetrating lubricant to fasteners

Procedure

1. 1

   Depressurize air suspension system
   Using the Rivian diagnostic tool, navigate to air suspension controls and select 'Deflate' for the specific corner being serviced. Monitor pressure readings until the air spring is fully deflated to 0 PSI. If diagnostic tool is unavailable, carefully disconnect the air line at the valve block while wearing eye protection, allowing air to escape slowly.
2. 2

   Disconnect air supply line
   Locate the air supply line connection at the top or side of the air spring assembly. Using the appropriate air line disconnect tool, press the release collar and pull the air line straight out of the fitting. Inspect the O-ring on the line for damage and replace if necessary. Cap or plug the line to prevent contamination.
3. 3

   Disconnect electrical connector
   If the air spring has an integrated height sensor or solenoid valve, locate the electrical connector. Press the locking tab and carefully disconnect the wiring harness. Secure the harness away from the work area to prevent damage.
4. 4

   Remove upper mounting fasteners
   Access the upper mounting point of the air spring, typically located in the wheel well or under an access panel. Remove the upper mounting nuts or bolts securing the air spring to the frame or body. Note the orientation and position of any washers or spacers for reinstallation.
5. 5

   Remove lower mounting fasteners
   Locate the lower mounting point where the air spring attaches to the suspension arm or axle assembly. Remove the lower mounting bolts while supporting the air spring. Be prepared for the spring to drop slightly once fasteners are removed.
6. 6

   Remove air spring assembly
   Carefully maneuver the air spring assembly out of its mounting location. This may require rotating or compressing the spring slightly to clear surrounding components. Inspect the mounting surfaces on both the frame and suspension arm for corrosion, damage, or debris.
7. 7

   Inspect mounting hardware and surfaces
   Thoroughly inspect upper and lower mounting plates, bushings, and hardware for wear, cracking, or corrosion. Clean all mounting surfaces with a wire brush. Check for proper alignment of mounting points - any misalignment may indicate suspension damage requiring additional repair.
8. 8

   Prepare new air spring
   Unpack the new air spring assembly and verify it matches the original part. Check that all mounting brackets are properly attached. If the air spring came shipped compressed, remove any shipping straps per manufacturer instructions. Lubricate O-rings on air fittings with silicone grease.
9. 9

   Install new air spring assembly
   Position the new air spring into the mounting location, ensuring proper orientation - the air line fitting should be accessible and positioned correctly. Align the upper and lower mounting points carefully before inserting fasteners.
10. 10

    Install and secure mounting fasteners
    Install the lower mounting bolts first, threading them by hand to ensure proper alignment. Then install upper mounting fasteners. Tighten all mounting hardware in a cross pattern to specification. Note: Without specific torque values provided, follow OEM service manual specifications exactly.
11. 11

    Reconnect electrical connector
    Reconnect the electrical connector to the height sensor or solenoid valve if equipped. Ensure the connector locks securely with an audible click. Verify wiring is properly routed and secured away from moving suspension components.
12. 12

    Reconnect air supply line
    Insert the air supply line straight into the fitting on the air spring until it seats completely - you should feel or hear it click into place. Gently pull on the line to verify it is securely locked. Ensure the line has adequate slack and will not be pinched during suspension travel.
13. 13

    Perform system pressurization and leak test
    Reconnect the 12V battery. Using the Rivian diagnostic tool, command the air suspension system to pressurize the newly installed air spring. Monitor the inflation process and listen for air leaks. Once at operating pressure, apply soapy water solution to all connections and fittings, watching for bubbles indicating leaks.

Reassembly

1. Reinstall wheel and tire assembly, torquing lug nuts to Rivian specification in star pattern
2. Lower vehicle from jack stands and remove lifting equipment
3. Use diagnostic tool to exit air suspension service mode and return to normal operation
4. Clear any diagnostic trouble codes related to the air suspension system
5. Remove wheel chocks

Verification

• Start vehicle and allow air suspension system to perform self-leveling routine
• Verify no warning lights or messages appear on instrument cluster related to air suspension
• Use diagnostic tool to verify height sensor readings are within normal range for all corners
• Perform test drive at low speed and verify proper ride height and suspension operation
• Recheck all fasteners for proper tightness after test drive
• Inspect air line connections once more for leaks after vehicle has cycled suspension through full range
• Verify even ride height at all four corners when vehicle is parked on level surface

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