This procedure covers the removal and replacement of the LED headlight module on a 2022 Rivian EDV 500 delivery van, including disconnecting electrical connections and securing the new module.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification
• Headlight mounting clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 10 minutes to allow systems to power down
3. Open front hood and disconnect 12V battery negative terminal
4. Wait 5 minutes after battery disconnect for capacitors to discharge
5. Verify headlight is completely cool if it was recently operated

Procedure

1. 1

   Access front fascia fasteners
   Open the front cargo area or access panel to reach the rear of the headlight assembly. Locate the access panel behind the headlight on the inner fender well. Some models may require partial removal of the front wheel well liner for full access.
2. 2

   Remove wheel well liner (if necessary)
   Turn the steering wheel fully to the opposite side of the headlight being replaced for better access. Remove the plastic push clips securing the front portion of the wheel well liner using the trim removal tool. Fold back the liner to expose the rear of the headlight assembly. Remove approximately 4-6 clips along the front edge only.
3. 3

   Disconnect headlight electrical connector
   Locate the main headlight electrical connector at the rear of the headlight assembly. Press the locking tab and pull the connector straight back from the headlight module. If connector is tight, gently rock it side to side while pulling. Inspect connector and pins for corrosion or damage.
4. 4

   Disconnect auxiliary connectors
   Disconnect the secondary connector for the LED daytime running light circuit if equipped as a separate connector. Some EDV 500 models integrate this into the main connector. Verify all electrical connections are disconnected before proceeding.
5. 5

   Remove headlight mounting fasteners
   Locate the headlight mounting bolts, typically three per headlight assembly. Remove the upper mounting bolt using the 10mm socket and extension. Remove the lower mounting bolt from below. Remove the lateral mounting bolt from the side of the assembly. Keep all fasteners organized for reinstallation.
6. 6

   Release headlight mounting clips
   Locate the spring-loaded retention clips at the bottom or sides of the headlight assembly. Use the trim removal tool to carefully release these clips by pressing inward and rotating. There are typically 2-3 clips in addition to the bolted mounting points.
7. 7

   Remove headlight assembly
   Carefully pull the headlight assembly forward and outward from the mounting location. The assembly may require angling to clear the fender and bumper cover. Support the assembly with both hands to prevent dropping. Set the old assembly on a clean, protected surface if it will be retained for core return.
8. 8

   Inspect mounting location
   Inspect the headlight mounting area for any damaged clips, broken tabs, or corrosion. Check that the alignment pins in the mounting location are intact. Clean any debris or moisture from the mounting surface and electrical connector area.
9. 9

   Prepare new headlight module
   Remove the new LED headlight module from its protective packaging. Verify the part number matches the original assembly. Check that all mounting tabs and alignment features are intact. Apply a small amount of dielectric grease to the electrical connector pins on the new module if desired for corrosion protection.
10. 10

    Install new headlight assembly
    Carefully align the new headlight assembly with the mounting location, ensuring alignment pins engage properly. Angle the assembly into position, clearing the fender and bumper cover. Press firmly but gently until the mounting clips engage with an audible click.
11. 11

    Install mounting fasteners
    Install the three mounting bolts hand-tight first to ensure proper alignment. Tighten the upper bolt first, then the lower, then the lateral bolt. Tighten bolts in a star pattern to ensure even seating. Tighten securely but do not overtighten as the mounting bosses are plastic.
12. 12

    Reconnect electrical connectors
    Connect the main headlight electrical connector to the rear of the new module, ensuring it clicks into place. Verify the locking tab is fully engaged. Connect the secondary DRL connector if equipped. Gently tug on connectors to verify secure attachment.
13. 13

    Reinstall wheel well liner
    If the wheel well liner was removed, reposition it and secure with the original push clips. Ensure all clips are fully seated and the liner is properly aligned to prevent rubbing or rattling.
14. 14

    Reconnect battery and test
    Reconnect the 12V battery negative terminal. Turn the vehicle to the ON position without starting (or ON mode for EV). Test all headlight functions including low beam, high beam, and daytime running lights. Check for proper operation and verify no warning lights are illuminated on the instrument cluster.

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify headlight assembly is flush with surrounding body panels and properly aligned
3. Check that all mounting fasteners are tightened and clips are engaged
4. Confirm wheel well liner is properly reinstalled if it was removed

Verification

• With vehicle in ON mode, verify low beam headlights illuminate properly on both sides
• Test high beam function and verify both headlights switch to high beam
• Check daytime running light operation if equipped
• Verify no warning lights or error messages appear on the instrument cluster
• Inspect headlight alignment and adjust if necessary using the headlight aim adjustment screws
• Check that headlight assembly is secure with no movement or rattling
• Road test vehicle at night to confirm proper headlight operation and beam pattern

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