Air Suspension Height Sensor

This procedure covers the removal and replacement of an air suspension height sensor on a 2024 Rivian EDV 500 electric delivery van with dual motor AWD and air suspension.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM specification
• Sensor mounting hardware kit × 1 — Use OEM specification
• Wire connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind wheels opposite to the corner being serviced
3. Connect diagnostic scan tool and enter air suspension service mode to lock suspension at current height
4. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
5. Raise vehicle using lift or floor jack and support with jack stands at appropriate lift points
6. Remove wheel and tire assembly from the corner where sensor is being replaced
7. Photograph sensor mounting position and wire routing for reference during installation

Procedure

1. 1

   Access the height sensor mounting area
   Remove the inner fender liner or wheel well trim panel to access the height sensor. The sensor is mounted to the suspension control arm and connects to the chassis via a link rod. Use trim panel tools to avoid damaging clips. On the EDV 500, sensors are typically located at the upper control arm mounting area.
2. 2

   Disconnect electrical connector
   Locate the electrical connector for the height sensor. Press the locking tab and carefully disconnect the connector. Inspect connector seals for damage or corrosion. If moisture is present, note this for parts replacement.
3. 3

   Document sensor position
   Before removal, note the exact position of the sensor link rod connection and any adjustment settings. The sensor must be reinstalled in the same position relative to suspension travel. Take measurements or additional photos if needed.
4. 4

   Disconnect sensor link rod
   Locate the ball joint connection or clip where the sensor link rod attaches to the suspension component. Remove the retaining clip or unsnap the ball joint connection. Support the link rod to prevent it from falling and damaging the sensor or connector.
5. 5

   Remove sensor mounting fasteners
   Remove the mounting bolts or screws securing the height sensor to its bracket on the chassis or suspension component. The EDV 500 typically uses two Torx or hex head fasteners. Keep hardware organized for comparison with new parts kit.
6. 6

   Remove height sensor assembly
   Carefully remove the height sensor from its mounting location. Note the orientation of the sensor body and any indexing features. Inspect the mounting bracket for damage or corrosion that may affect new sensor installation.
7. 7

   Prepare new sensor
   Unpack the new height sensor and compare it to the old unit to verify correct part. Check that all mounting hardware is included. If the sensor has an adjustable link rod, set it to match the length of the original sensor using your measurements from Step 3.
8. 8

   Install new sensor to mounting bracket
   Position the new height sensor onto the mounting bracket, ensuring proper orientation and alignment. Install the mounting fasteners but do not fully tighten yet to allow for final positioning adjustment.
9. 9

   Connect sensor link rod
   Attach the sensor link rod to the suspension component using the ball joint or clip connection. Ensure the connection is fully seated and secure. Verify the sensor is at the correct angle relative to suspension travel range.
10. 10

    Finalize sensor mounting
    With the link rod connected, verify the sensor position matches your reference photos and measurements. Tighten the sensor mounting fasteners fully. Ensure the sensor has adequate clearance from suspension components throughout the full range of travel.
11. 11

    Connect electrical connector
    Route the sensor wiring harness following the original path. Connect the electrical connector to the height sensor, ensuring it clicks into place and the locking tab engages. Replace connector seals if they were damaged during removal.
12. 12

    Secure wiring harness
    Secure the sensor wiring harness to the chassis or suspension using the original wire tie locations. Ensure adequate slack for suspension movement and verify the harness will not contact moving components or sharp edges throughout suspension travel.
13. 13

    Perform sensor calibration
    Using the diagnostic scan tool, access the air suspension calibration menu. Select the specific corner where the sensor was replaced. Follow the on-screen prompts to perform the height sensor calibration procedure, which typically involves cycling the suspension through its full range and setting reference points.

Reassembly

1. Reinstall inner fender liner or wheel well trim panel, ensuring all clips are fully seated
2. Reinstall wheel and tire assembly and tighten lug nuts to specification
3. Lower vehicle from jack stands to ground
4. Reconnect 12V battery negative terminal
5. Exit air suspension service mode using diagnostic scan tool
6. Allow suspension system to self-level and verify proper operation at all height settings

Verification

• Start vehicle and verify no suspension fault codes are present in the diagnostic system
• Use scan tool to monitor live data from the replaced height sensor, confirming signal output changes smoothly as suspension moves
• Cycle through all available suspension height settings and verify vehicle achieves correct ride height at each setting
• Perform a test drive and verify normal suspension operation, proper ride height maintenance, and no warning lights
• After test drive, re-check for any stored fault codes and verify ride height remains correct after various driving conditions
• Inspect sensor mounting area for any signs of contact or interference with suspension components during full articulation

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