This procedure covers the removal and replacement of the air spring (air bag) suspension component on the 2025 Rivian EDV 500 delivery van equipped with Dual Motor AWD.

Warnings

Tools required

Parts

• Air spring assembly × 1 — Use OEM Rivian specification
• Air line O-rings × 2 — Included with air spring kit
• Upper mount hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Connect diagnostic tool and record current air suspension height settings and calibration values
3. Place wheel chocks at opposite corners from repair location
4. Lift vehicle using appropriate lift points specified in Rivian service manual for EDV 500
5. Support vehicle on jack stands rated for commercial EV weight
6. Remove wheel and tire assembly at corner requiring air spring replacement
7. Verify high-voltage system is in service mode if working near HV components

Procedure

1. 1

   Enter air suspension service mode
   Using the Rivian diagnostic tool, navigate to the air suspension module. Select service mode to vent all air pressure from the system. Wait for confirmation that system is fully depressurized. This typically takes 2-3 minutes. Verify air compressor is disabled and will not activate during service.
2. 2

   Disconnect air supply line
   Locate the air supply line connection at the top or side of the air spring assembly. Press the release collar on the push-to-connect fitting and carefully pull the air line away from the air spring. Inspect the line for damage or contamination. Cap or plug the air line end to prevent debris entry.
3. 3

   Disconnect height sensor linkage
   Locate the height sensor link arm connected to the suspension component near the air spring. Remove the retaining clip and disconnect the ball joint or rod end from the mounting point. Note the orientation and position for reinstallation. Some models may have an electrical connector at the sensor that must also be disconnected.
4. 4

   Support lower control arm
   Position a hydraulic jack or jack stand under the lower control arm to support the suspension weight. Raise slightly to take load off the air spring but do not compress suspension. This prevents sudden dropping of suspension components during air spring removal.
5. 5

   Remove upper mounting hardware
   Access the upper air spring mount from inside the wheel well or through the chassis access panel. Remove the mounting nuts or bolts securing the upper mount to the chassis. On EDV 500, this typically involves 3-4 fasteners arranged in a circular pattern. Support the air spring assembly as you remove the final fastener.
6. 6

   Remove lower mounting hardware
   Locate and remove the lower mounting bolts that secure the air spring to the lower control arm or axle mount. The EDV 500 typically uses 2-3 bolts at the lower mount. Apply penetrating oil if fasteners show corrosion. Note the orientation of any alignment tabs or locating features.
7. 7

   Remove air spring assembly
   Carefully guide the air spring assembly out from between the chassis and suspension components. The air spring may be compressed or extended depending on suspension position. Rotate and maneuver as needed to clear brake lines, wiring harnesses, and other components. Inspect mounting surfaces on chassis and suspension for corrosion or damage.
8. 8

   Prepare mounting surfaces
   Clean both upper and lower mounting surfaces using a wire brush to remove rust, debris, or old sealant. Inspect mounting studs or threaded inserts for damage. Apply thin coat of anti-seize compound to mounting studs (avoid threaded holes). Replace any damaged hardware. Ensure mounting surfaces are flat and free of debris that could affect air spring sealing.
9. 9

   Install new air spring assembly
   Position the new air spring between the mounting points, ensuring proper orientation. Align any locating tabs or pins with their corresponding slots. Start the lower mounting fasteners first, threading by hand to prevent cross-threading. Do not fully tighten yet. Align the upper mount and install upper mounting hardware finger-tight.
10. 10

    Torque mounting hardware
    Torque the lower mounting bolts to manufacturer specification using a crisscross pattern if multiple bolts are present. Then torque the upper mounting nuts or bolts in a star pattern to ensure even loading. Since specific torque values are not provided in the database, consult the Rivian EDV 500 service manual for exact specifications, typically in the range of 35-50 ft-lbs for suspension mounting hardware.
11. 11

    Reconnect height sensor linkage
    Reattach the height sensor link arm to its mounting point on the suspension. Install the retaining clip and ensure the connection is secure. Verify the sensor arm moves freely through its range of motion without binding. Reconnect any electrical connectors to the height sensor if applicable.
12. 12

    Connect air supply line
    Install new O-rings on the air spring fitting if provided with the replacement part. Push the air supply line firmly into the air spring connection until you hear or feel it click into place. Gently tug on the line to verify it is fully seated and locked in the fitting. Ensure the line is routed correctly without kinks or contact with moving components.
13. 13

    Remove support and reinstall wheel
    Carefully lower and remove the jack supporting the lower control arm. Reinstall the wheel and tire assembly, torquing lug nuts to Rivian EDV 500 specification (typically 150-175 ft-lbs for commercial vehicles, consult service manual for exact value).
14. 14

    Exit service mode and pressurize system
    Using the diagnostic tool, exit air suspension service mode. The system will automatically begin pressurizing. Monitor the air spring inflation through the diagnostic tool. Verify the new air spring inflates evenly and reaches target pressure. This process typically takes 3-5 minutes. Listen for air leaks around all connections.
15. 15

    Perform system calibration
    With the vehicle at normal ride height, perform the air suspension calibration procedure using the diagnostic tool. This recalibrates the height sensors and ensures proper system operation. Follow the on-screen prompts which typically involve cycling the suspension through various height positions. Clear any stored fault codes related to the air spring replacement.

Reassembly

1. Reinstall any access panels or trim pieces removed for service access
2. Lower vehicle to ground and remove jack stands
3. Torque wheel lug nuts to final specification in a star pattern with vehicle on ground
4. Test drive vehicle at various speeds and observe suspension performance
5. Verify no air leaks are present by listening around connections after vehicle has been sitting for 30 minutes

Verification

• Using diagnostic tool, verify no active or pending air suspension fault codes are present
• Confirm all four corners (if applicable) are at proper ride height and balanced
• Test air suspension height adjustment functions through all programmed settings
• Verify height sensor readings are within normal range and responding to vehicle movement
• Perform visual inspection for air leaks at all connection points around the new air spring
• Test drive vehicle over various road surfaces to ensure normal suspension operation and no unusual noises
• Confirm air compressor duty cycle is normal (should not run continuously after initial pressurization)

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