Brake Booster Check Valve

Replace or inspect the brake booster check valve on a 2022 Rivian EDV 500 electric delivery van to ensure proper vacuum assist for braking performance.

Warnings

Tools required

Parts

• Brake booster check valve × 1 — Use OEM Rivian specification
• Vacuum hose (if damaged) × 1 — Use OEM specification
• Hose clamps (if needed) × 2 — Use appropriate size for vacuum line

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn off vehicle completely and remove key fob from cabin
3. Open hood and secure with prop rod
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
5. Locate the electric vacuum pump assembly on the driver side of the engine bay near the brake master cylinder
6. Take photos of vacuum hose routing for reference during reassembly
7. Verify you have the correct replacement check valve that matches OEM specifications

Procedure

1. 1

   Access the brake booster vacuum system
   Remove any plastic engine covers or trim panels obstructing access to the brake booster and vacuum pump assembly. On the EDV 500, this typically requires removing the upper cabin air filter housing trim if present. The electric vacuum pump is mounted near the brake master cylinder on the driver side firewall.
2. 2

   Identify the check valve location
   Locate the check valve in the vacuum line between the electric vacuum pump and the brake booster. The check valve is typically a cylindrical component in-line with the vacuum hose, positioned to allow flow toward the booster while preventing backflow. It may be integrated into the booster inlet or in the hose itself.
3. 3

   Test the existing check valve
   Before removal, test the check valve function. Disconnect the vacuum hose from the brake booster side of the check valve. Using a vacuum pump tester, apply vacuum to the booster side of the valve - it should hold vacuum. Then attempt to apply vacuum from the pump side - it should allow vacuum to pass through. If the valve fails either test, replacement is necessary.
4. 4

   Relieve vacuum system pressure
   Press the brake pedal 15-20 times with the vehicle off and 12V battery disconnected to fully exhaust any stored vacuum in the brake booster. The pedal should become progressively harder with each press.
5. 5

   Disconnect vacuum pump electrical connector
   Locate the electrical connector on the electric vacuum pump. Press the locking tab and carefully disconnect the connector. Secure it away from the work area to prevent damage.
6. 6

   Remove vacuum hose from pump side
   Using needle nose pliers, compress or release the hose clamp securing the vacuum line to the electric pump outlet. Carefully twist and pull the hose to remove it from the pump fitting. If the hose is brittle or cracked, plan to replace it.
7. 7

   Remove vacuum hose from booster side
   Release the hose clamp or retaining mechanism securing the vacuum line to the brake booster inlet. The check valve may be integrated into this connection point. Carefully remove the hose, noting the orientation of the check valve arrow which indicates proper flow direction toward the booster.
8. 8

   Extract the check valve
   If the check valve is a separate in-line component, cut or remove it from the vacuum hose. If it is pressed into the booster inlet, carefully pry or twist it out using a flathead screwdriver, being careful not to damage the booster inlet port. Clean the connection points with a wire brush or contact cleaner.
9. 9

   Install the new check valve
   Install the new check valve in the correct orientation - the arrow on the valve body MUST point toward the brake booster. If installing in-line, insert it firmly into the vacuum hose with equal length on both sides. If installing into the booster inlet, press firmly until fully seated with no gap visible.
10. 10

    Reconnect vacuum hoses
    Attach the vacuum hose from the electric pump to the check valve inlet, ensuring the connection is fully seated. Install a new hose clamp if the original is damaged. Then connect the booster side, again verifying full seating and proper clamp installation. Ensure no kinks or sharp bends exist in the hose routing.
11. 11

    Reconnect vacuum pump electrical connector
    Plug the electrical connector back onto the vacuum pump until it clicks into place. Verify the locking tab is fully engaged.
12. 12

    Reconnect 12V battery
    Reconnect the negative terminal on the 12V auxiliary battery. The vehicle may require a brief initialization period for the brake system to ready itself.

Reassembly

1. Reinstall any trim panels or engine covers removed during disassembly
2. Verify all vacuum hose connections are secure with no leaks
3. Ensure all electrical connectors are fully seated and locked
4. Check brake fluid level in the master cylinder reservoir and top off with DOT 4 brake fluid if needed

Verification

• With the vehicle off, press the brake pedal and hold. Start the vehicle - the pedal should drop slightly as vacuum assist activates, indicating proper check valve and pump operation
• Listen for the electric vacuum pump to run briefly at startup or when the brake pedal is pressed several times. It should cycle on to restore vacuum
• Check for vacuum leaks by listening near all hose connections with the pump running
• Perform a stationary brake test - the brake pedal should feel firm but not excessively hard, indicating proper power assist
• In a safe, empty area, perform a low-speed brake test (under 15 mph) to verify normal brake assist function and pedal feel before returning to normal service
• Use a diagnostic scanner if available to check for any brake system fault codes
• If brake pedal is excessively hard or brake warning lights illuminate, do NOT drive the vehicle - recheck all connections and test the check valve function again

Related trouble codes on this vehicle

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