Air Line

This procedure covers the inspection, repair, or replacement of pneumatic air supply lines in the 2025 Rivian EDV 500's air brake or air suspension system.

Warnings

Tools required

Parts

• Air line assembly or section × 1 — Use OEM specification - varies by location
• Push-to-connect air line fittings × 2 — Use OEM specification
• O-rings for air fittings × 4 — Use OEM specification
• Air line mounting clips × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage electronic parking brake
2. Place wheel chocks at all four wheels
3. Disconnect 12V auxiliary battery negative terminal to disable electrical systems
4. Locate the air system service valve (typically near air compressor in rear chassis area)
5. Open air system drain valves to fully depressurize all air reservoirs - listen for air release until completely silent
6. Verify zero pressure on air pressure gauge in driver information display or use external gauge
7. Raise vehicle on lift or support securely on jack stands at manufacturer-specified lift points
8. Remove any underbody panels or wheel well liners necessary to access the damaged air line section
9. Identify the specific air line requiring service and trace routing from component to component
10. Take photos of air line routing and connection points for reference during reinstallation

Procedure

1. 1

   Inspect air line damage and determine repair scope
   Carefully inspect the damaged air line section to determine if a splice repair is possible or if complete line replacement is necessary. Check for cracks, abrasion damage, melting from exhaust heat, or fitting leaks. Trace the line from end-to-end to identify all connection points. For air brake systems, any damage to primary brake circuit lines requires complete replacement - splicing is not permitted per FMVSS regulations.
2. 2

   Release air line from mounting clips
   Locate all mounting clips and brackets securing the air line along its route. Release the line from plastic push-clips by gently prying the clip open with a trim tool. For metal brackets with rubber grommets, the line may need to be cut first before removal. Note the exact position and orientation of each clip for proper reinstallation.
3. 3

   Disconnect air line at upstream connection
   At the upstream connection point (typically at the air reservoir, valve, or compressor), identify the fitting type. For push-to-connect (PTC) fittings, insert the appropriate size air line disconnect tool into the collar while gently pulling the air line straight out. Do not twist or bend the line during removal as this can damage the fitting. For compression fittings, use two wrenches to hold the body fitting while loosening the compression nut. Inspect the fitting for debris or damage.
4. 4

   Disconnect air line at downstream connection
   Move to the downstream connection point (at brake chamber, height control valve, or other component). Use the same disconnection technique as upstream. If fittings are corroded or seized, apply penetrating oil and allow 10 minutes to soak before attempting removal. Do not force fittings as the component ports can be damaged, requiring much more extensive repairs.
5. 5

   Remove damaged air line from vehicle
   Carefully extract the air line from the vehicle, noting how it routes around frame members, wiring harnesses, and other components. If the line passes through frame holes or bulkhead grommets, note the grommet orientation and condition. Replace any damaged grommets to prevent chafing of the new line. Keep the old line as a routing reference.
6. 6

   Prepare new air line for installation
   Using the old line as a template, measure and cut the new air line to the exact length required. Air line must be cut with a sharp blade perpendicular to the line to ensure proper sealing in push-to-connect fittings - do not use scissors or pinch-cutters which can deform the end. Ensure the cut end is clean, square, and free of debris. If installing new fittings, verify that new O-rings are properly seated in the fitting bodies.
7. 7

   Route new air line through chassis
   Beginning at the upstream connection, route the new air line following the exact path of the original. Ensure minimum 2-inch clearance from exhaust components, sharp edges, and moving parts (suspension, driveshaft). When passing through frame holes or grommets, protect the line from chafing. Maintain natural curves without kinks - air line should not have any radius tighter than 6 inches. Do not pull the line taught; allow some slack for suspension movement and vibration.
8. 8

   Connect air line at upstream fitting
   For push-to-connect fittings, push the air line firmly into the fitting until it bottoms out and you feel positive engagement (typically 15-20mm insertion depth). Give the line a firm pull to verify it is locked in place - it should not move. For threaded compression fittings, insert line fully, hand-tighten compression nut, then use wrenches to tighten an additional 1 to 1.5 turns while holding the body fitting stationary. Do not overtighten as this can deform the line.
9. 9

   Secure air line in mounting clips
   Install the air line into all mounting clips and brackets following your reference photos. Clips should be positioned to support the line every 18-24 inches and at any direction change. Ensure clips hold the line securely but do not pinch or compress it. Replace any broken mounting clips with OEM parts - do not substitute zip ties on air brake systems as they can fail from vibration.
10. 10

    Connect air line at downstream fitting
    Connect the downstream end using the same technique as the upstream connection. Verify the line routing one final time to ensure no interference with suspension travel, steering components, or tire clearance at full lock and compression. Check that the line does not contact any sharp edges or hot components.
11. 11

    Pressurize air system and check for leaks
    Close all air system drain valves. Reconnect the 12V auxiliary battery. Start the vehicle to activate the air compressor. Monitor the air system pressure gauge as it builds pressure - system should reach full operating pressure (typically 120-130 PSI) within 3-5 minutes on a fully depleted system. Listen for any obvious air leaks during pressurization.
12. 12

    Perform leak detection test
    With the system at full pressure and compressor shut off, apply leak detection solution or soapy water to all new connections and along the entire new air line section. Watch for bubble formation indicating leaks. Check both ends of the air line and any intermediate fittings. If any leaks are detected at push-to-connect fittings, depressurize system, disconnect, inspect fitting and line end for damage, and reconnect. If leaks persist, replace the fitting and/or cut a fresh end on the air line.
13. 13

    Perform air system pressure drop test
    With system at full operating pressure, shut off vehicle and observe pressure gauge. Note initial pressure reading. After 5 minutes, pressure drop should not exceed 2-3 PSI with brakes released. Apply and hold service brake for 1 minute - pressure should remain stable. This verifies system integrity. If excessive pressure drop occurs, re-inspect all connections and repeat leak detection test.

Reassembly

1. Reinstall any underbody panels or wheel well liners removed during access, ensuring they do not contact or interfere with the new air line routing
2. Lower vehicle from lift or jack stands
3. Remove wheel chocks
4. Verify all tools and parts have been removed from vehicle
5. Test parking brake engagement and release function multiple times to verify air system operation

Verification

• Start vehicle and verify air system builds to full pressure within normal time frame (3-5 minutes)
• Check driver information display for any air system warning lights or fault codes
• Perform a low-speed test drive in a safe area and apply brakes firmly several times to verify proper brake function
• After test drive, perform a final visual inspection of the air line installation and verify no new leaks have developed
• For commercial vehicles, perform a post-repair air brake system inspection per FMVSS 121 or local regulations before returning to service
• Document the repair including air line location, part numbers used, and leak test results in vehicle maintenance records

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