This procedure covers the removal and replacement of an air spring (air bag) on a 2023 Rivian EDV 500 delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks at opposite end from the corner being serviced
3. Connect diagnostic scan tool and enter service mode for air suspension
4. Use scan tool to exhaust air from the specific air spring being replaced
5. Disconnect 12V battery negative terminal and wait 2 minutes
6. Raise vehicle on lift or jack stands ensuring proper contact points per Rivian service manual
7. Remove wheel and tire from corner being serviced
8. Support the lower control arm or axle with a jack stand to prevent overextension when air spring is removed

Procedure

1. 1

   Access air spring upper mounting area
   Remove interior cargo area trim panels or access panels as needed to expose the upper air spring mount. For rear air springs, this typically requires removing the lower cargo panel on the affected side. Use trim removal tools to avoid damaging clips.
2. 2

   Disconnect air supply line
   Locate the air supply line connected to the top of the air spring. Press the release collar on the quick-connect fitting and carefully pull the air line free from the air spring. Inspect the O-ring on the air line fitting and replace if damaged or worn.
3. 3

   Disconnect height sensor connector
   Locate the ride height sensor attached to the air spring or nearby suspension component. Press the locking tab and disconnect the electrical connector. Secure the connector away from the work area to prevent damage.
4. 4

   Remove upper mounting fasteners
   Remove the upper air spring mounting bolts or nuts. There are typically 2-3 fasteners securing the top plate of the air spring to the chassis. Support the air spring assembly to prevent it from dropping when the last fastener is removed.
5. 5

   Remove lower mounting fasteners
   Working from beneath the vehicle, locate and remove the lower air spring mounting fasteners that secure the air spring to the lower control arm or axle mounting bracket. Note the orientation and position of any alignment features or spacers.
6. 6

   Remove air spring assembly
   Carefully lower and extract the air spring assembly from between the upper and lower mounts. The air spring may need to be rotated or maneuvered around nearby suspension components, brake lines, or sensors. Inspect the mounting surfaces on both the chassis and suspension for corrosion or damage.
7. 7

   Inspect and clean mounting surfaces
   Thoroughly clean both upper and lower air spring mounting surfaces. Remove any corrosion, debris, or old sealant. Inspect the mounting studs or bolt holes for thread damage. Check the rubber bump stops and protective boots for deterioration.
8. 8

   Install new air spring assembly
   Position the new air spring between the upper and lower mounting locations. Ensure proper orientation by aligning any indexing features or air line positioning. Carefully raise the assembly into position using the support jack if needed to align the mounting holes.
9. 9

   Install lower mounting fasteners
   Install the lower air spring mounting fasteners through the lower control arm or axle bracket. Hand tighten initially to allow for final positioning. Ensure any spacers or alignment washers are correctly positioned.
10. 10

    Install upper mounting fasteners
    Install the upper air spring mounting fasteners through the chassis mounting points. Hand tighten initially, then torque all upper and lower mounting fasteners to specification once all are started. Note: Specific torque values not available in database - refer to Rivian factory service manual.
11. 11

    Reconnect air supply line
    Install new O-rings on the air line fitting if provided with the replacement air spring. Push the air supply line firmly into the quick-connect fitting on top of the air spring until it clicks into place. Gently tug on the line to verify it is fully seated and locked.
12. 12

    Reconnect height sensor
    Reconnect the ride height sensor electrical connector to the sensor. Ensure the connector locks securely with an audible click. Verify the sensor linkage moves freely and is properly attached to both the air spring or chassis and the suspension component.
13. 13

    Reinstall trim panels and wheel
    Reinstall all interior cargo area trim panels and access covers removed during disassembly. Ensure all clips are properly seated. Reinstall the wheel and tire, hand tightening lug nuts in a star pattern.
14. 14

    Lower vehicle and reconnect battery
    Carefully lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern (refer to Rivian service manual for specific torque value). Reconnect the 12V battery negative terminal.
15. 15

    Initialize and calibrate air suspension
    Using the diagnostic scan tool, exit service mode and command the air suspension system to inflate the replaced air spring. Monitor system pressure and check for air leaks at the air line connection. Perform a ride height calibration procedure using the scan tool to ensure proper vehicle leveling and sensor operation.

Reassembly

1. All mounting fasteners should be torqued to Rivian specifications as no torque values are currently in the database
2. Ensure air line quick-connect fitting is fully seated and locked before pressurizing the system
3. Verify all electrical connectors are fully engaged and locked
4. Double-check that no tools or parts were left in the suspension area before lowering vehicle

Verification

• Start the vehicle and observe the air suspension system inflate to normal ride height without error messages
• Use diagnostic scan tool to verify no fault codes are present in the air suspension system
• Check for air leaks by listening near the air line connection and air spring body while system is pressurized
• Verify the ride height sensor is reading properly and the affected corner is level with the rest of the vehicle
• Perform a test drive and verify normal suspension operation, proper ride height maintenance, and no unusual noises
• Recheck all mounting fasteners for proper torque after test drive
• Verify vehicle self-levels correctly when parked and when loading/unloading cargo

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