Air Suspension Height Sensor

This procedure covers the removal and replacement of an air suspension height sensor on a 2023 Rivian EDV 500 delivery van, including recalibration of the suspension system.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM specification
• Height sensor mounting hardware kit × 1 — Use OEM specification
• Wiring harness connector seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Using Rivian diagnostic software, command the air suspension to normal ride height mode and allow system to stabilize
3. Chock both front wheels if working on rear sensor, or rear wheels if working on front sensor
4. Disconnect the 12V battery negative terminal and wait 2 minutes before proceeding
5. Identify which corner sensor requires replacement (LF, RF, LR, or RR) based on diagnostic trouble codes
6. Take photos of sensor orientation and wiring routing for reference during installation
7. Ensure you have the vehicle-specific calibration values from Rivian service documentation

Procedure

1. 1

   Raise and support vehicle
   Using a floor jack, raise the affected corner of the vehicle at the designated jacking point. Place jack stands under the frame rails for support. Do not rely on the air suspension to support the vehicle. Lower the vehicle onto the jack stands, ensuring the suspension can droop freely but the tire remains on the ground or is just slightly raised.
2. 2

   Remove wheel and access panels
   Remove the wheel on the affected corner using appropriate socket. If working on a front sensor, remove the inner fender liner plastic fasteners and fold back the liner for access. If working on a rear sensor, remove the rear wheelwell access panel or cargo area side trim panel as needed to access the sensor mounting location and electrical connector.
3. 3

   Locate and document sensor position
   Locate the height sensor mounted to the suspension control arm and frame. The sensor consists of a mounting bracket on the frame, the sensor body, and a link arm connected to the lower control arm or axle. Take detailed photos showing the exact angle and position of the sensor link arm in relation to the suspension components. Note the current position of any adjustment nuts or mounting positions.
4. 4

   Disconnect sensor electrical connector
   Trace the sensor wiring harness to the electrical connector. Release the connector lock tab by pressing or sliding it as designed. Carefully disconnect the electrical connector from the height sensor. Inspect the connector pins and seal for corrosion or damage. If corrosion is present, clean with electrical contact cleaner and allow to dry.
5. 5

   Disconnect sensor link arm
   Locate the ball joint or pin connection where the sensor link arm attaches to the suspension control arm. Remove the retaining clip, cotter pin, or bolt securing the link arm to the suspension. Carefully disconnect the link arm from the suspension component, noting its exact position and angle. Support the link arm to prevent it from falling.
6. 6

   Remove sensor from frame bracket
   Locate the mounting bolts or screws securing the height sensor body to the frame bracket. Using the appropriate socket or wrench, remove the sensor mounting hardware. Some sensors may use a slotted mounting bracket for adjustment - note the exact position of the sensor in the slots before removal. Carefully remove the sensor assembly from the vehicle.
7. 7

   Inspect mounting locations
   Inspect the frame mounting bracket for cracks, corrosion, or damage. Check the suspension link arm connection point for wear or deformation. Use a wire brush to clean any corrosion from mounting surfaces. Verify that the mounting holes are not elongated or damaged. If the frame bracket is damaged, it must be replaced before installing the new sensor.
8. 8

   Install new height sensor
   Position the new height sensor in the frame mounting bracket, aligning it exactly as the original sensor was positioned based on your reference photos. Install the mounting hardware finger-tight initially. Ensure the sensor body is oriented correctly with the electrical connector accessible and not under strain. If using a slotted bracket, position the sensor in the same slot position as the original.
9. 9

   Connect sensor link arm
   Carefully position the sensor link arm to connect to the suspension control arm or axle mounting point. Ensure the suspension is in the correct position (approximately normal ride height with vehicle on jack stands). Connect the link arm ball joint or pin connection, ensuring it is fully seated. Install the retaining clip, cotter pin, or bolt as designed. Verify the link arm moves freely through its full range of motion without binding.
10. 10

    Final sensor positioning and securing
    With the link arm connected and the suspension at approximately normal ride height, verify the sensor angle matches your reference photos. The sensor link arm should typically be at a near-horizontal or slightly angled position at normal ride height. Tighten all sensor mounting hardware securely. For slotted brackets, ensure the sensor cannot shift in the slots. Double-check that the sensor has adequate clearance from suspension components throughout the full range of suspension travel.
11. 11

    Reconnect electrical connector
    Route the sensor wiring harness as originally configured, using existing clips and securing points. Ensure the wiring has adequate slack and will not be pinched or stretched during suspension movement. Connect the electrical connector to the height sensor, ensuring it clicks or locks fully into place. Gently tug on the connector to verify it is secure. If the connector seal was damaged, replace it with a new seal.
12. 12

    Reinstall access panels and wheel
    Reinstall any inner fender liners, wheelwell panels, or cargo area trim panels removed for access. Ensure all fasteners are properly seated. Reinstall the wheel and hand-tighten the lug nuts. Raise the vehicle slightly, remove the jack stands, and lower the vehicle to the ground. Torque the wheel lug nuts to Rivian specification in a star pattern.
13. 13

    Reconnect battery and initialize system
    Reconnect the 12V battery negative terminal. Turn the ignition to the ON position without starting the drive motors. Allow the vehicle systems to initialize fully, which may take 1-2 minutes. The air suspension system will perform self-checks and may adjust ride height automatically.
14. 14

    Calibrate height sensor using diagnostic software
    Connect the Rivian diagnostic interface and laptop to the vehicle's diagnostic port. Launch the Rivian service software and navigate to the air suspension module. Select the height sensor calibration procedure for the replaced sensor corner. Follow the on-screen prompts to calibrate the sensor, which typically involves commanding the suspension through various height positions while the sensor learns its range. Enter any vehicle-specific calibration values if required. Complete the calibration procedure and verify no fault codes are present.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify sensor link arm has full range of motion without interference
3. Confirm all mounting hardware is torqued to specification once torque values are available
4. Secure all wiring harnesses with original clips or new zip ties to prevent chafing
5. Double-check that all trim panels and wheelwell liners are reinstalled completely

Verification

• Clear any stored fault codes using Rivian diagnostic software and perform a test drive
• Using diagnostic software, monitor the height sensor output voltage or position reading - it should change smoothly as the suspension moves
• Command the air suspension to all available height settings (access, normal, off-road if equipped) and verify the vehicle achieves correct ride height at each setting
• Drive the vehicle at various speeds and observe that the suspension maintains proper ride height without fault codes
• Verify the instrument cluster does not display any suspension warning lights or messages
• Perform a final scan for diagnostic trouble codes - there should be no active suspension faults
• Check that the affected corner maintains the same ride height as the opposite corner when parked on level ground

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