electrical

Headlight Assembly - Pair

for 2023 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Difficulty

Moderate

Time

2.6 h

Tools

Steps

This procedure covers the removal and installation of both left and right headlight assemblies on the 2023 Rivian EDV 500 electric delivery van.

Warnings

⚠️Disconnect 12V battery before beginning work to prevent electrical shock or short circuit. The high voltage system remains isolated but 12V accessories can cause injury.

⚠Headlight assemblies are fragile and expensive. Handle carefully to avoid cracking lenses or damaging internal LED components.

⚠Do not touch LED or reflector surfaces with bare hands. Oils from skin can cause hot spots and premature failure.

ℹ️This vehicle uses sealed LED headlight assemblies. Individual bulbs cannot be replaced; the entire assembly must be replaced if LEDs fail.

Tools required

10mm socket and ratchetEssential

8mm socket and ratchetEssential

Trim panel removal tool setEssential

T25 Torx driverEssential

Flathead screwdriver

Electrical contact cleaner

Microfiber cloth

Painter's tape

Parts

Left headlight assembly × 1 — Use OEM specification
Right headlight assembly × 1 — Use OEM specification
Headlight mounting clips/hardware × 1 — Usually included with assembly
Electrical connector seals × 2 — Replace if damaged

Preparation

Park vehicle on level surface and engage parking brake
Turn off all vehicle systems and remove key fob from vehicle interior
Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
If headlight assembly is damaged, protect surrounding paint with painter's tape
Photograph headlight mounting and connector orientation for reference during reassembly

Procedure

1
Access front bumper fascia clips
Open the hood and locate the upper bumper fascia clips along the top edge behind the leading edge of the hood opening. There are approximately 8-10 push clips securing the top of the bumper fascia. Use a trim removal tool to carefully pry up the center of each clip to release them.
2
Remove front wheel well liner fasteners
Turn the steering wheel to full lock away from the side being serviced. Remove the T25 Torx screws and push clips securing the front portion of the wheel well liner to the bumper fascia. You only need to release the forward-most section, not the entire liner. Fold back the liner to access the side mounting points of the headlight assembly.
3
Disconnect headlight electrical connectors
Reach behind the headlight assembly and locate the main headlight connector (large multi-pin connector). Press the locking tab and pull the connector straight back to disconnect. Locate the secondary connector for the daytime running light or adaptive lighting module if equipped, and disconnect it using the same method. Mark connectors with tape if working on both sides simultaneously.
⚠Do not pull on wires. Always grasp the connector body and use the release tab to avoid damaging pins or wiring.
4
Remove upper headlight mounting fasteners
From the engine compartment, locate the two 10mm bolts at the top of the headlight assembly. These are typically positioned along the upper edge near the hood latch area. Remove both bolts completely and set aside. Note any alignment shims or spacers present and keep them with the fasteners.
5
Remove lower and side mounting fasteners
Locate the lower mounting bolt accessible from below the headlight assembly (8mm or 10mm depending on position). Access through the wheel well opening. Remove this bolt. Locate the side mounting fastener accessible from the wheel well area (typically one 8mm bolt or T25 screw). Remove this fastener completely.
6
Release headlight assembly from bumper clips
With all fasteners removed, gently pull the headlight assembly forward and outward. The assembly is secured by alignment clips on the inboard side that fit into slots in the body structure. Rock the assembly gently while pulling to release these clips. Be prepared to support the weight of the assembly as it comes free.
⚠The assembly may be stuck due to sealant or debris. Do not force it. Check that all fasteners have been removed before applying excessive force.
7
Remove headlight assembly
Once released from the clips, carefully maneuver the headlight assembly out of the vehicle. Tilt and angle as necessary to clear the bumper fascia and fender structures. Place the assembly on a clean, padded surface with the lens facing up to prevent scratching. Cover with a clean cloth.
8
Inspect mounting points and clean surfaces
Inspect the mounting brackets on the vehicle for damage, corrosion, or loose hardware. Clean the mounting surface and alignment pins with a clean cloth. Remove any old sealant residue if present. Inspect electrical connectors for corrosion or damage; clean with electrical contact cleaner if needed.
9
Prepare new headlight assembly
Remove new headlight assembly from packaging carefully. Verify it matches the side being replaced (left or right). Check that all connector seals are present and properly seated. Do not remove protective film from lens until installation is complete. Transfer any alignment shims from the old assembly if required.
10
Install new headlight assembly
Position the new headlight assembly near the mounting location. Align the inboard clips with their corresponding slots in the body structure. Carefully angle the assembly into position and press firmly to engage the alignment clips. Verify the assembly is fully seated and the gaps around the perimeter are consistent with the opposite side.
11
Install mounting fasteners
Install the side mounting fastener through the wheel well access and hand-tighten. Install the lower mounting bolt and hand-tighten. Install the two upper mounting bolts with any alignment shims in their original positions and hand-tighten. Once all fasteners are started, tighten them in sequence: upper bolts first, then lower bolt, then side fastener. Tighten snugly but do not overtighten as this can crack the mounting tabs.
12
Reconnect electrical connectors
Reconnect the main headlight electrical connector by aligning the pins and pushing firmly until the locking tab clicks into place. Tug gently to verify it is secure. Reconnect the secondary connector for DRL or adaptive lighting if equipped. Verify both connectors are fully seated and locked.
13
Reinstall wheel well liner
Reposition the front wheel well liner to its original position. Install all T25 Torx screws and push clips that were removed. Ensure the liner is properly aligned and does not interfere with any moving components or wiring.
14
Reinstall bumper fascia clips
Align the front bumper fascia to its original position. Install all push clips along the top edge by pressing the outer portion into the body, then pushing the center pin down to lock. Verify the fascia is properly seated along its entire length with consistent gaps.
15
Repeat for opposite side
If replacing both headlight assemblies, repeat steps 2 through 14 for the opposite side of the vehicle. Use the same procedures and precautions for the second assembly.

Reassembly

Reconnect the 12V battery negative terminal and tighten securely
Remove any protective film from headlight lenses
Remove painter's tape from surrounding areas if used
Close hood and verify all trim panels are secure with no gaps or misalignment

Verification

Turn on vehicle systems and verify both headlights illuminate in low beam mode
Activate high beams and verify both headlights switch to high beam mode
Test turn signals and daytime running lights on both sides
If equipped, verify adaptive headlight function by turning steering wheel lock-to-lock with headlights on
Inspect headlight alignment - both beams should point in the same direction with similar cutoff patterns
Perform full headlight alignment procedure if beams appear misaligned or if vehicle will be driven at night before professional alignment
Check for any error messages on instrument cluster related to lighting systems
Inspect all fasteners and trim pieces for proper installation and security
Verify no gaps exist between headlight assembly and surrounding body panels