Air Line

This procedure covers the inspection, repair, or replacement of compressed air supply lines on the Rivian EDV 500 commercial van, including suspension and brake system air lines.

Warnings

Tools required

Parts

• Air line assembly × 1 — Use OEM specification
• Air line push-to-connect fittings × 4 — Use OEM specification
• Air line mounting clips × 6 — Use OEM specification
• Thread sealant tape (PTFE) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Using scan tool, place vehicle in service mode to disable high-voltage systems
5. Raise vehicle on lift to working height, ensuring proper contact with frame lift points
6. Access air suspension control module (located behind driver-side rear trim panel) and initiate depressurization sequence
7. Wait 5 minutes after depressurization before beginning work
8. Take detailed photos of air line routing, especially where lines pass through frame rails and near electrical harnesses

Procedure

1. 1

   Locate and inspect air line damage
   Identify the specific air line requiring service. For the EDV 500, air lines run from the compressor (located in right rear cargo area) to each corner air spring, with distribution block mounted to frame rail behind front axle. Visually inspect for cracks, abrasion, kinks, or disconnected fittings. Check routing for interference with suspension components during full travel.
2. 2

   Remove cargo area trim panels (if accessing compressor)
   If servicing lines near the compressor, remove right rear cargo area side trim panel. Release six push clips along bottom edge and two screws at top. Disconnect courtesy light connector if equipped. Set panel aside in protected area.
3. 3

   Disconnect air line at compressor or distribution block
   Using air line disconnect tool, depress the locking collar on the push-to-connect fitting while pulling the air line straight out. Do not twist or bend the line during removal. If fitting is corroded or stuck, apply penetrating oil and wait 10 minutes before attempting removal again. Label the line with tape indicating which port it connects to.
4. 4

   Release air line from chassis mounting clips
   Working from compressor/distribution block toward the air spring, release each mounting clip securing the air line to the frame rail or body. The EDV 500 typically uses 6-8 clips per line. Note clip locations and condition; replace any broken clips. Gently pull line through any frame pass-throughs or grommets.
5. 5

   Disconnect air line at air spring assembly
   Access the air spring connection point at the suspension corner. For front suspension, this requires turning wheel to full lock for access. For rear, access from wheelwell. Use air line disconnect tool to release push-to-connect fitting at air spring top mount. Support the air line as you disconnect to prevent it from falling.
6. 6

   Remove damaged air line from vehicle
   Carefully extract the complete air line assembly from the vehicle, noting routing path through frame channels and around components. Verify the replacement line matches original length and fitting configuration before proceeding.
7. 7

   Inspect and clean connection points
   Inspect all push-to-connect fittings at compressor, distribution block, and air spring for damage or debris. Clean fitting surfaces with lint-free cloth. Check O-rings inside fittings for cuts or deterioration; replace fittings if O-rings are damaged. Blow out any debris from ports using compressed air.
8. 8

   Route new air line through chassis
   Following the documented routing from preparation photos, feed the new air line through frame channels and pass-throughs. Ensure line follows original path and maintains minimum 2-inch clearance from exhaust components, drive axles, and steering linkage. Route away from sharp edges and ensure adequate slack for suspension travel.
9. 9

   Install air line mounting clips
   Secure the new air line using mounting clips at original locations. Ensure clips are fully engaged and line is not kinked or twisted. The line should be snug but not under tension. Verify minimum clearance of 1 inch from moving suspension components throughout full suspension travel range.
10. 10

    Connect air line to air spring
    Push the air line firmly into the push-to-connect fitting at the air spring until you feel and hear a positive click. Gently tug on the line to verify it is locked in place. The line should not pull free with moderate hand pressure.
11. 11

    Connect air line to compressor or distribution block
    Push the opposite end of the air line into the appropriate port on the compressor or distribution block until it clicks into place. Verify connection by pulling gently on the line. Cross-reference with your labels to ensure correct port assignment.
12. 12

    Pressurize system and perform leak test
    Reconnect 12V battery. Using scan tool, exit service mode and initiate air suspension system pressurization. Allow system to reach normal operating pressure (approximately 3-5 minutes). Apply soap and water solution to all new connections and inspect for bubbles indicating air leaks. If leaks are detected, depressurize system, disconnect fitting, inspect O-ring, and reconnect.
13. 13

    Verify system operation
    Using scan tool, command each air spring to raise and lower independently to verify proper air flow through the new line. Monitor system pressure and listen for unusual hissing or leaks. Check that the affected corner responds normally to ride height commands. Clear any diagnostic trouble codes related to air suspension if present.

Reassembly

1. Reinstall cargo area trim panels if removed, ensuring all clips are fully seated and electrical connectors are secured
2. Lower vehicle from lift and remove wheel chocks
3. Perform final visual inspection of air line routing from all accessible angles
4. Take the vehicle for a test drive over varied terrain to verify suspension operation and listen for air leaks

Verification

• Verify no diagnostic trouble codes are present in air suspension system using scan tool
• Confirm all four corners rise and lower equally when ride height adjustments are commanded
• Inspect all new air line connections for leaks using soap solution with system at operating pressure
• Verify proper ride height is maintained after vehicle sits overnight (no significant pressure loss)
• Confirm air line has adequate clearance from all moving components through full suspension travel
• Test drive vehicle and verify normal suspension operation with no air leaks audible from cargo area or wheelwells

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