Complete replacement of both left and right headlight assemblies on the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification
• Right headlight assembly × 1 — Use OEM specification
• Headlight mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 15 minutes to allow systems to power down
3. Open hood and secure with prop rod
4. Disconnect 12V battery negative terminal and wait 2 minutes
5. Protect front bumper and fenders with masking tape or soft cloth to prevent scratches
6. Document or photograph existing headlight aim settings if adjustment markings are visible

Procedure

1. 1

   Access front bumper fasteners
   Remove the front grille cover by releasing the upper clips using trim panel removal tools. Start at the center and work outward. The grille is secured with approximately 8-10 push clips along the top edge.
2. 2

   Remove front bumper cover screws
   Remove the Torx T25 screws securing the front bumper cover to the fenders (2 per side). Remove the T20 screws along the top bumper edge near the headlight locations (approximately 4 screws total). Lower screws may be accessed from wheel well area.
3. 3

   Partially release bumper cover
   Gently pull the front bumper cover forward at the headlight areas to create clearance. Do not fully remove the bumper - only pull forward 2-3 inches to access headlight mounting bolts. Support the bumper to prevent stress on lower mounting points.
4. 4

   Disconnect driver side headlight electrical connector
   Locate the main headlight connector behind the left headlight assembly. Press the release tab and pull the connector straight back. There may be a secondary connector for the DRL/turn signal - disconnect this as well. Note connector orientation for reinstallation.
5. 5

   Remove driver side headlight mounting fasteners
   Remove the three 10mm bolts securing the left headlight assembly. Typically one bolt is located at the top, one at the inner fender area, and one at the lower outer corner. Keep track of any spacers or washers.
6. 6

   Extract driver side headlight assembly
   Carefully pull the left headlight assembly forward and outward at an angle. Guide the rear of the assembly through the opening while supporting its weight. Be careful not to scratch the lens or contact surrounding body panels. Set assembly on protected surface.
7. 7

   Disconnect passenger side headlight electrical connector
   Access the right headlight connector behind the assembly. Press the release tab and disconnect the main connector and any secondary connectors. Verify no wiring harness clips or tie wraps need to be released.
8. 8

   Remove passenger side headlight mounting fasteners
   Remove the three 10mm bolts securing the right headlight assembly in the same configuration as the driver side. Check for and retain any mounting hardware, spacers, or alignment shims.
9. 9

   Extract passenger side headlight assembly
   Remove the right headlight assembly using the same careful technique as the left side. Support the assembly weight and guide it out without contacting body panels. Inspect the mounting area for any debris or corrosion.
10. 10

    Prepare new headlight assemblies
    Remove protective covers from new headlight assemblies. Inspect lenses for shipping damage. Do not remove any protective film from lenses until after installation. Verify mounting points align with removed assemblies.
11. 11

    Install new driver side headlight
    Guide the new left headlight assembly into position at an angle, inserting the rear portion first. Align mounting holes and loosely install all three 10mm bolts with any original spacers or shims. Do not fully tighten yet to allow for alignment adjustment.
12. 12

    Connect driver side electrical connectors
    Connect the main headlight connector until it clicks into place. Connect any secondary connectors. Ensure no wiring is pinched and connectors are fully seated with locking tabs engaged.
13. 13

    Install new passenger side headlight
    Install the right headlight assembly following the same procedure as the left. Align mounting points and loosely install all mounting bolts. Verify assembly sits flush with surrounding body panels before tightening.
14. 14

    Connect passenger side electrical connectors
    Connect all electrical connectors for the right headlight assembly. Ensure proper seating and locking tab engagement. Route wiring to avoid pinch points.
15. 15

    Final alignment and tightening
    Adjust both headlight assemblies to ensure even gaps with hood, fenders, and bumper. Tighten all mounting bolts gradually in a cross pattern to prevent misalignment. Verify assemblies are secure and gaps are uniform on both sides.

Reassembly

1. Push front bumper cover back into position and verify all clips align properly
2. Reinstall all Torx screws securing bumper cover to fenders and upper mounting points
3. Reinstall front grille cover by pressing clips into position until they snap securely
4. Reconnect 12V battery negative terminal
5. Remove any protective tape or coverings from body panels
6. Remove protective film from headlight lenses

Verification

• Turn ignition to ON position and verify both headlights illuminate on low beam
• Test high beam function on both sides
• Verify DRL and turn signal operation on both headlights
• Check for any error messages or warning lights on instrument cluster
• Inspect headlight alignment visually - both beams should appear level when aimed at a wall from 25 feet
• Verify all headlight mounting bolts are tight and assemblies do not move when pressed
• Check that all bumper cover fasteners are secure and gaps are even
• Schedule or perform professional headlight aim adjustment to ensure proper beam patterns and legal compliance

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