electrical

Headlight Bulb - Single

for 2022 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Difficulty

Moderate

Time

2.0 h

Tools

Steps

This procedure covers the replacement of a single headlight bulb assembly on a 2022 Rivian EDV 500 commercial delivery van, which requires removal of the front bumper cover and headlight assembly due to the integrated sealed LED design.

Warnings

⚠️Disconnect 12V auxiliary battery before beginning work to prevent electrical shorts and system faults. The high-voltage system does not need to be disconnected for this procedure.

⚠Rivian EDV 500 headlights are sealed LED assemblies. Individual bulbs cannot be replaced - the entire headlight assembly must be replaced if the LED fails.

⚠Do not force plastic clips or trim pieces. Broken clips will require replacement and may cause wind noise or water intrusion.

ℹ️This vehicle uses an aluminum body structure. Be careful not to scratch or gouge painted surfaces during disassembly.

Tools required

Plastic trim removal tool setEssential

10mm socket and ratchetEssential

T20 Torx driverEssential

T25 Torx driverEssential

Extension set (3-inch and 6-inch)Essential

Masking tape

Clean microfiber cloth

Flashlight or work lightEssential

Parts

Headlight assembly (LED) × 1 — Use OEM Rivian specification - driver or passenger side specific
Push-pin retaining clips × 5 — Replacement for any broken clips during removal

Preparation

Park vehicle on level surface and ensure parking brake is engaged
Disconnect 12V auxiliary battery located in the front trunk area - remove negative terminal first
Wait 5 minutes after battery disconnect to allow capacitors to discharge
Apply masking tape to surrounding painted surfaces near the bumper and headlight to prevent accidental scratches
Identify whether you are replacing driver side or passenger side headlight and verify correct replacement part
Take photos of clip and fastener locations before removal for reference during reassembly

Procedure

1
Remove front wheel well liner clips
Turn steering wheel fully to opposite side of headlight being replaced for access. Remove the three push-pin clips securing the front section of the wheel well liner to the bumper cover. Use plastic trim tool to pry center pins up first, then remove entire clip assembly. Store clips in a container.
2
Fold back wheel well liner
Carefully pull the front section of the wheel well liner away from the bumper area to expose the side mounting points of the bumper cover. You should be able to see the rear edge of the headlight assembly and bumper mounting bracket.
3
Remove lower bumper cover fasteners
From underneath the front of the vehicle, locate and remove four T25 Torx screws along the lower edge of the bumper cover. These are located between the wheel wells. Remove two additional 10mm bolts at the lower corners near each wheel well.
4
Remove upper bumper cover fasteners
Open the front trunk (frunk). Locate and remove six push-pin clips along the top edge of the bumper cover where it meets the hood opening. Remove three T20 Torx screws on each side of the upper bumper mounting area.
5
Disconnect bumper sensors and remove bumper
With an assistant supporting the bumper cover, carefully pull the bumper cover forward at the corners to release the side clips. Disconnect the wiring harnesses for parking sensors (typically 4 connectors along the bumper). Press the locking tabs and pull connectors straight out. Remove bumper cover completely and place on a padded surface.
6
Remove headlight assembly upper fasteners
Locate the three T25 Torx screws securing the top of the headlight assembly to the mounting bracket. Remove all three screws and retain them. These are accessible from above with the bumper removed.
7
Remove headlight assembly side and lower fasteners
Remove the two 10mm bolts on the outboard side of the headlight assembly. Remove one additional T25 Torx screw at the lower corner of the headlight mounting bracket. Keep all fasteners organized by location.
8
Disconnect headlight electrical connector
Locate the main headlight electrical connector at the rear of the headlight assembly. Press the release tab (red or gray locking mechanism) and pull the connector straight back from the headlight. Do not pull on wires. If connector is difficult to remove, gently rock it side to side while pulling.
9
Remove headlight assembly
Carefully pull the headlight assembly forward and away from the vehicle. The assembly has locating pins that fit into rubber grommets - you may need to wiggle the assembly slightly to release them. Support the assembly weight as you remove it to prevent dropping.
10
Prepare new headlight assembly
Inspect the new headlight assembly for any shipping damage. Transfer any mounting brackets or hardware if they did not come pre-installed on the new unit. Verify that rubber grommets and locating pin seals are properly seated on the new assembly.
11
Install new headlight assembly
Align the locating pins on the new headlight assembly with the mounting points on the vehicle body. Push the assembly straight back into position until the mounting holes align and the assembly is fully seated. Ensure the assembly sits flush with no gaps.
12
Reconnect electrical connector and install fasteners
Connect the main electrical harness to the rear of the new headlight assembly - it should click into place. Tug gently to verify secure connection. Install the side and lower fasteners first (two 10mm bolts and one T25 Torx screw), then install the three upper T25 Torx screws. Tighten fasteners in a star pattern to ensure even seating.
13
Reinstall front bumper cover
With an assistant, position the bumper cover and reconnect all four parking sensor connectors. Align the bumper side clips first, then push the bumper into place. Install all fasteners in reverse order: upper push-pins and T20 screws from the frunk area, lower T25 screws and 10mm bolts from underneath. Ensure all clips are fully seated.
14
Reinstall wheel well liner
Fold the wheel well liner back into position and install the three push-pin clips. Push the outer portion of each clip in first, then press the center pin down until flush. Verify the liner is properly seated with no gaps.

Reassembly

Reconnect the 12V auxiliary battery - positive terminal first, then negative terminal
Verify all push-pins, clips, and fasteners are fully seated and secure
Check that bumper cover is aligned properly with even gaps around hood and fenders
Remove all masking tape and clean any fingerprints from new headlight lens with microfiber cloth

Verification

Turn vehicle to ON mode (press brake and push start button without drive mode selected)
Turn on headlights and verify both low and high beams function on the new assembly
Test turn signal and running lights on the replaced side
Activate parking sensors and verify no error messages appear on the instrument cluster
Check for proper headlight aim - headlights should point slightly downward and to the right (driver side) or left (passenger side). Professional alignment may be required
Verify all dashboard warning lights related to lighting system are off
Visually inspect for any gaps in bumper cover or wheel well liner that could allow water intrusion
Take a short test drive and verify no rattles or wind noise from bumper area