Air Line

This procedure covers the inspection, replacement, or repair of compressed air lines in the 2023 Rivian EDV 500 pneumatic system, including brake system air supply lines and air suspension components.

Warnings

Tools required

Parts

• Air line assembly × 1 — Use OEM specification
• Air line compression fittings × 4 — Use OEM specification
• O-ring seal kit × 1 — Use OEM specification
• Push-to-connect fittings × 2 — Use OEM specification
• Air line mounting clips × 6 — Use OEM specification

Preparation

1. Park the vehicle on a level surface and engage the parking brake
2. Verify that the battery is at least 50% charged to maintain system operation during diagnostics
3. Connect the Rivian diagnostic scan tool and document any existing fault codes
4. Enable the high voltage system lockout mode through the diagnostic interface
5. Allow the air suspension system to reach normal ride height and stabilize for at least 2 minutes
6. Access the pneumatic system menu via the scan tool and initiate system depressurization sequence
7. Wait for the air compressor to shut down and verify system pressure has dropped below 10 PSI using the scan tool live data
8. Remove any underbody panels or wheel well liners necessary to access the affected air line routing
9. Photograph the air line routing and mounting locations for reference during reassembly
10. Clean the work area around the air line connections to prevent contamination

Procedure

1. 1

   Verify System Depressurization
   Using the air pressure gauge, verify that the pneumatic system is fully depressurized by checking the pressure at the compressor tank test port. Pressure must read 0 PSI before proceeding. If pressure remains above 0 PSI, use the scan tool to command the air release solenoid open manually.
2. 2

   Locate and Identify Air Line
   Identify the specific air line requiring service by tracing from the affected component (air spring, compressor, or distribution block). The EDV 500 uses color-coded air lines: blue for front axle, red for rear axle, and black for compressor supply. Verify you have identified the correct line before disconnecting.
3. 3

   Disconnect Air Line at First Fitting
   Using the pneumatic line disconnect tool, depress the release collar on the push-to-connect fitting while simultaneously pulling the air line straight out. Do not twist or bend the line during removal. If the fitting is corroded or seized, apply penetrating lubricant and wait 5 minutes before attempting removal again. Cap the open fitting immediately with a clean plug to prevent contamination.
4. 4

   Remove Mounting Clips
   Release each air line mounting clip along the line routing path. The EDV 500 uses spring-loaded clips that can be released by pressing the locking tab while sliding the clip away from the air line. Note the exact position and orientation of each clip for proper reinstallation.
5. 5

   Disconnect Air Line at Second Fitting
   Repeat the disconnection process at the opposite end of the air line. Support the line during removal to prevent it from dropping and contacting sharp edges or hot components. Check the area around the fitting for any additional retaining brackets or tie-downs that must be released.
6. 6

   Inspect Fittings and Seals
   Examine both push-to-connect fittings on the component side for wear, cracks, or damage. Inspect the O-rings inside each fitting for cuts, flattening, or deterioration. Replace any damaged fittings or O-rings. Clean the fitting bores with a lint-free cloth and inspect for debris or corrosion.
7. 7

   Prepare New Air Line
   If installing a new air line, verify the part number matches the application and the length is correct. Cut the line end square using a proper tube cutter if field-cutting is required (do not use side cutters or knives). Deburr the cut end with a deburring tool and wipe clean. Apply a small amount of approved pneumatic lubricant to the line end for easier insertion.
8. 8

   Install Air Line at First Connection
   Insert the air line straight into the push-to-connect fitting until it bottoms out, then pull back gently to verify engagement. You should feel resistance indicating the collet has gripped the line. The line should be inserted approximately 15-18mm past the fitting face for proper seal engagement.
9. 9

   Route Air Line
   Route the new or repaired air line following the original path documented in the preparation photos. Ensure the line does not contact any sharp edges, hot surfaces (motor housings), moving components, or high voltage cables. Maintain at least 50mm clearance from the drive units and battery pack housing.
10. 10

    Install Mounting Clips
    Reinstall all air line mounting clips in their original positions. Ensure each clip is fully seated and the line is properly captured without being pinched or kinked. The line should have slight slack between mounting points to allow for suspension movement without straining the connections.
11. 11

    Connect Air Line at Second Fitting
    Complete the installation by connecting the second end of the air line using the same insertion technique. Verify proper engagement by tugging on the line with moderate force. The line should not pull free from the fitting.
12. 12

    Perform Leak Test
    Using the scan tool, command the air compressor to pressurize the system to normal operating pressure (approximately 120 PSI). Apply leak detection solution to all connections and fittings. Monitor for bubbles indicating air leaks for at least 60 seconds. If leaks are detected, depressurize the system and reseat the affected connection.
13. 13

    System Function Test
    With the system pressurized, command each air suspension corner to raise and lower through the scan tool to verify proper air flow through the repaired line. Monitor system pressure during operation to ensure it maintains pressure and the compressor duty cycle is normal. Check for unusual hissing sounds indicating leaks.
14. 14

    Clear Fault Codes and Verify
    Clear all pneumatic system fault codes using the scan tool. Exit lockout mode and restore normal vehicle operation. Perform a test drive including suspension mode changes to verify proper system operation. Re-scan for fault codes after the test drive to confirm no new issues have been logged.

Reassembly

1. Reinstall all underbody panels and wheel well liners using the original fasteners
2. Verify all air line mounting clips are secure and the lines are not rubbing against any surfaces
3. Torque all panel fasteners to manufacturer specifications if available
4. Verify no tools or parts have been left in the work area

Verification

• Perform a final visual inspection of all air line connections and routing
• Verify system pressure maintains at least 100 PSI after sitting for 30 minutes with the vehicle off (indicates no significant leaks)
• Confirm all air suspension functions operate correctly through the vehicle interface
• Verify no pneumatic system fault codes are present in the diagnostic system
• Test drive the vehicle through various suspension height modes and verify smooth operation without fault messages
• Document the repair in the vehicle service history with date, mileage, and parts replaced

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