Air Suspension Height Sensor

This procedure covers the removal and replacement of an air suspension height sensor on a 2022 Rivian EDV 500 delivery van with dual motor AWD and factory air suspension system.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM Rivian specification
• Sensor mounting hardware kit (if corroded) × 1 — Use OEM specification
• Electrical connector seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at all wheels not being serviced
3. Connect Rivian diagnostic tool and enter air suspension service mode to lower vehicle to access height
4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
5. Raise and support vehicle at manufacturer-specified lift points
6. Remove wheel and tire assembly on corner where sensor is being replaced
7. Locate height sensor on suspension control arm or knuckle assembly

Procedure

1. 1

   Access height sensor location
   Remove inner fender liner or wheel well splash shield as necessary to access the height sensor. The sensor is typically mounted to the lower control arm with a link arm connecting to the chassis or subframe. Use trim tools to release push clips and Torx fasteners securing the liner.
2. 2

   Document sensor orientation
   Before removal, photograph or note the exact orientation and position of the height sensor and its link arm. Note the routing of the electrical connector and any securing clips. This reference is critical for proper reinstallation and calibration.
3. 3

   Disconnect electrical connector
   Locate the electrical connector for the height sensor, typically positioned away from direct road spray. Press the connector release tab and carefully disconnect. Inspect connector pins for corrosion or damage. If connector seal shows deterioration, mark for replacement.
4. 4

   Disconnect sensor link arm
   The height sensor uses a pivoting link arm connected to a ball stud on the chassis or control arm. Remove the retaining clip (typically an E-clip or spring clip) from the ball stud connection point. Carefully pry the link arm off the ball stud. Note any washers or spacers and their order.
5. 5

   Remove sensor mounting fasteners
   Remove the mounting bolts securing the height sensor to its bracket on the control arm or chassis. These are typically 10mm bolts. If fasteners show corrosion, use penetrating oil and a wire brush. Support the sensor during removal to prevent it from falling.
6. 6

   Remove height sensor assembly
   Carefully extract the height sensor from its mounting location, routing the electrical connector through any clips or brackets. Inspect the mounting location for corrosion, damage, or debris. Clean mounting surfaces with a wire brush if necessary.
7. 7

   Inspect and prepare mounting area
   Examine the ball stud connection points for wear or damage. Check that the chassis mounting bracket is secure and not bent. Clean all mounting surfaces and ball studs. Apply dielectric grease to electrical connector sealing surfaces to prevent future corrosion.
8. 8

   Install new height sensor
   Position the new height sensor in the mounting bracket, aligning bolt holes. Install mounting bolts and tighten evenly by hand initially. Route the electrical connector following the original path, ensuring it will not contact moving suspension components or areas exposed to excessive heat.
9. 9

   Connect sensor link arm
   Attach the sensor link arm to the ball stud on the chassis or control arm, ensuring any spacers or washers are in their original positions. Install the retaining clip, ensuring it is fully seated in the groove. Verify the link arm pivots freely without binding through full suspension travel.
10. 10

    Connect electrical connector
    Route the electrical connector to its mating connector and firmly press together until the locking tab clicks. Gently tug to verify secure connection. Secure the connector and wiring harness to any factory clips or routing brackets to prevent chafing.
11. 11

    Reinstall wheel well components
    Reinstall the inner fender liner or splash shield, ensuring all push clips and Torx fasteners are properly seated. Verify no wiring or sensor components are pinched or interfered with by the liner.
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel and tire assembly, installing lug nuts in a star pattern. Tighten lug nuts to manufacturer specification. Lower the vehicle to the ground and perform final lug nut torque with vehicle weight on wheels.
13. 13

    Reconnect battery and exit service mode
    Reconnect the 12V auxiliary battery negative terminal. Connect the Rivian diagnostic tool and exit air suspension service mode. The system will perform self-diagnostics and may adjust ride height automatically.
14. 14

    Calibrate height sensor
    Using the Rivian diagnostic tool, access the air suspension module and perform height sensor calibration procedure. This typically involves allowing the vehicle to settle, verifying all doors are closed, and initiating the calibration routine. Follow all on-screen prompts and allow the system to cycle through various height positions.
15. 15

    Clear diagnostic codes and verify operation
    Clear any stored suspension fault codes from the system. Cycle the air suspension through all available height settings (access, normal, off-road if equipped) using the vehicle controls. Verify smooth operation and absence of new fault codes. Take a short test drive and recheck for codes.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify sensor link arm moves freely through full suspension travel without binding
3. Confirm all wheel well liners and splash shields are properly secured
4. Double-check wheel lug nuts are torqued to specification after test drive

Verification

• Use diagnostic tool to verify height sensor is reporting values within normal range
• Manually cycle air suspension through all height modes and verify proper operation
• Check for any suspension-related fault codes in vehicle computer
• Verify ride height is level side-to-side and front-to-rear when vehicle is in normal mode
• Perform test drive including turns and bumps to ensure suspension responds correctly
• Confirm sensor connector is sealed and protected from water intrusion

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