This procedure replaces both headlight bulb assemblies on the 2022 Rivian EDV 500 electric delivery van, requiring removal of front fascia components and headlight housing access panels.

Warnings

Tools required

Parts

• LED headlight assembly × 2 — Use OEM Rivian specification
• Headlight housing seal/gasket × 2 — Use OEM specification if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from cabin
3. Open hood and secure with prop rod
4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system capacitors to discharge
5. Mark or photograph front fascia panel positions with masking tape for proper reassembly alignment
6. Ensure replacement headlight assemblies match vehicle production date and part revision

Procedure

1. 1

   Remove front wheel well liner clips
   Turn steering wheel fully to one side to access wheel well. Remove the five push-pin fasteners securing the front portion of the wheel well liner to access the back of the headlight assembly. Use trim removal tool to prevent breaking clips.
2. 2

   Remove front bumper fascia upper clips
   Open hood and locate the six T20 Torx screws along the top edge of the front bumper fascia. Remove all screws and store together. Gently pull forward on fascia upper edge to release the four hidden push-clips behind the grille area.
3. 3

   Disconnect headlight electrical connector
   Reach behind the headlight assembly through the wheel well opening. Locate the main headlight harness connector (large gray connector with orange safety lock). Press down on the orange safety tab and slide it toward the vehicle rear. Squeeze the connector release tab and pull straight back to disconnect.
4. 4

   Remove headlight assembly mounting fasteners
   Locate the three T30 Torx bolts securing the headlight assembly: one on top accessed from engine bay, one on the inner fender side accessed through wheel well, and one on the bottom accessed from below. Remove all three bolts completely and store safely.
5. 5

   Extract headlight assembly
   With all fasteners removed, carefully pull the headlight assembly forward and outward from the front of the vehicle. The assembly has locating pins at the rear that must clear their grommets. Angle the outboard edge forward first, then slide the entire assembly out. Place on clean, padded surface.
6. 6

   Inspect mounting points and seal condition
   Examine the headlight mounting area for any damage, corrosion, or debris. Check the condition of the rubber seal gasket on the back of the removed headlight. If the seal is torn, compressed permanently, or degraded, it should be replaced to prevent moisture intrusion.
7. 7

   Prepare new headlight assembly
   Remove new headlight assembly from protective packaging. Verify correct part number matches removed unit. If reusing seal gasket, transfer it to the new assembly ensuring it seats properly in the groove. If using new seal, install it around the perimeter of the assembly backing plate.
8. 8

   Install new headlight assembly
   Align the new headlight assembly with the mounting location. Insert the locating pins at the rear of the assembly into their corresponding grommets in the body structure. Push assembly rearward until it seats flush against the body panel. Ensure the outboard edge aligns with the fender contour.
9. 9

   Install mounting fasteners
   Install the three T30 Torx mounting bolts: top bolt first (finger tight), then inner fender bolt, then bottom bolt. Once all three are started, tighten in sequence starting with top bolt. Tighten snugly but do not overtighten as you are threading into plastic bosses or captured nuts.
10. 10

    Reconnect electrical connector
    Route the headlight harness connector to the back of the new assembly. Align connector and push firmly until you hear and feel a click. Slide the orange safety lock back toward the front of vehicle to secure connector. Gently tug on harness to confirm locked connection.
11. 11

    Repeat process for opposite side
    Perform steps 1 through 10 for the opposite side headlight assembly. Ensure both sides are installed with equal alignment and gaps relative to surrounding body panels before proceeding.
12. 12

    Reinstall wheel well liner and fascia
    Reinstall the wheel well liner push-pin fasteners on both sides, ensuring liner sits flush and does not interfere with tire rotation. Align the front bumper fascia using reference marks made during disassembly. Reinstall the six T20 Torx screws along the top edge and press fascia firmly to engage the four push-clips.
13. 13

    Reconnect 12V battery and test operation
    Reconnect the 12V auxiliary battery negative terminal. Close hood. Turn vehicle to ON position and verify both headlights illuminate properly. Test low beam, high beam, and daytime running light functions. Check for any warning messages on instrument cluster.

Reassembly

1. Verify all trim panels and fascia components are fully seated with no gaps or misalignment
2. Confirm all push-pin fasteners and screws are installed and none were left out
3. Verify wheel well liners do not contact tires during full steering lock in both directions
4. Check that headlight beam pattern appears symmetrical between left and right sides

Verification

• With vehicle in ON mode, verify both headlights illuminate in all modes: DRL, low beam, and high beam
• Perform visual inspection from front of vehicle to confirm both headlights are aligned evenly and gaps to surrounding panels are consistent
• Check for moisture or condensation inside headlight lenses after installation (there should be none)
• Verify no warning lights or error messages appear on instrument cluster related to exterior lighting
• Test turn signals and marker lights integrated into headlight assemblies to confirm full functionality
• Drive vehicle in dark conditions and verify headlight aim is correct and provides adequate road illumination

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