This procedure covers removal and installation of the headlight assembly on a 2022 Rivian EDV 500 electric delivery van, including disconnecting electrical connections and releasing mounting hardware.

Warnings

Tools required

Parts

• Headlight assembly × 1 — Use OEM specification - specify left or right side
• Headlight mounting grommets × 3 — Use OEM specification
• Push pin retainers × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all electrical systems and remove key fob from vehicle interior
3. Open hood and secure with prop rod
4. Disconnect negative terminal of 12V auxiliary battery located in front compartment
5. Wait minimum 3 minutes for capacitor discharge in lighting control modules
6. Protect front bumper and fender with soft cloth or masking tape to prevent scratching during work
7. Identify which headlight assembly requires replacement (driver or passenger side)

Procedure

1. 1

   Access front bumper cover fasteners
   Remove the upper grille panel push pin retainers using trim removal tool. There are four push pins securing the upper section. Pull upward gently on grille panel after releasing fasteners to create access to headlight mounting area.
2. 2

   Remove wheel well liner access panel
   Turn steering wheel full lock away from the side being serviced. Locate the front wheel well liner access panel directly behind headlight assembly. Remove three T25 Torx screws securing the access panel. Fold panel back to expose rear headlight mounting location.
3. 3

   Disconnect headlight electrical connector
   Reach behind headlight assembly and locate the main headlight connector - a large gray multi-pin connector. Press down on the red locking tab while pulling connector straight back away from headlight. Do not pull on wiring harness. The connector has approximately 8 inches of slack when released.
4. 4

   Disconnect auxiliary lighting connectors
   Locate and disconnect two smaller connectors for daytime running lights (white connector) and turn signal/position lights (black connector). These use push-button releases. Press button and pull connector away from headlight assembly housing.
5. 5

   Remove upper headlight mounting fasteners
   From the engine compartment, locate two T30 Torx bolts at the top of the headlight assembly. These are positioned along the upper edge. Remove both bolts completely and set aside. The headlight assembly will now be loose but still captured by lower mounting points.
6. 6

   Remove lower headlight mounting fastener
   Through the wheel well access opening, locate the single 10mm bolt at the lower rear corner of the headlight assembly. Remove this bolt using a socket with extension. This is the primary lower retention point.
7. 7

   Release headlight assembly alignment pins
   The headlight assembly is positioned on three locating pins with rubber grommets. From the front, gently pull the headlight assembly forward while supporting its weight. Rock assembly slightly side-to-side if needed to release from locating pins. The assembly weighs approximately 8 pounds.
8. 8

   Remove headlight assembly from vehicle
   Carefully maneuver the headlight assembly out of the vehicle, feeding the rear section through the wheel well opening first, then rotating forward section out. Take care not to contact painted surfaces. Place assembly on protected work surface with lens facing upward.
9. 9

   Inspect mounting points and transfer components
   Inspect the three locating pins on vehicle body for damage. Replace rubber grommets if torn or compressed. If reusing headlight assembly, verify all mounting grommets on back of assembly are intact. Transfer any aiming adjustment components from old to new assembly if applicable.
10. 10

    Install new headlight assembly
    Position new headlight assembly at installation angle, inserting rear section through wheel well opening first. Align the three mounting grommets on rear of assembly with the three locating pins on vehicle body. Press firmly until grommets fully seat on pins with audible click.
11. 11

    Install mounting fasteners
    Install lower 10mm bolt through wheel well access and tighten finger-tight. Install both upper T30 Torx bolts and tighten finger-tight. Once all three fasteners are started, tighten in sequence: upper bolts first, then lower bolt. Ensure headlight assembly sits flush with fender and bumper gaps are even.
12. 12

    Reconnect electrical connectors
    Reconnect the three electrical connectors in reverse order: main headlight connector (gray) first, ensuring red locking tab clicks into place, then DRL connector (white), then turn signal connector (black). Verify each connector is fully seated and locked.
13. 13

    Reinstall access panels
    Reinstall wheel well liner access panel with three T25 Torx screws. Reinstall upper grille panel and secure with four push pin retainers. Ensure all panels are flush and properly seated.

Reassembly

1. Reinstall all trim panels and fasteners removed during disassembly
2. Reconnect negative terminal of 12V auxiliary battery and tighten securely
3. Verify all electrical connectors are fully seated and locked before testing
4. Remove protective masking tape or cloth from painted surfaces

Verification

• Turn vehicle to ON position without starting drive motors
• Activate headlights and verify low beam, high beam, and daytime running lights function correctly on replaced assembly
• Test turn signals and verify proper operation and flash rate
• Check for any warning lights or messages on instrument cluster related to lighting systems
• Visually inspect headlight aim - both headlights should point in same general direction; if aim is significantly off, headlight aiming procedure must be performed
• Verify no gaps or misalignment between headlight assembly and adjacent body panels
• Test vehicle on short drive and recheck all functions including automatic headlight leveling if equipped

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