This procedure covers the removal and replacement of the headlight assembly on a 2023 Rivian EDV 500 electric delivery van, including disconnecting electrical connectors and removing mounting hardware.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification
• Push-pin retainers (if damaged) × 5 — 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. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Open hood and secure with prop rod
5. Allow vehicle to sit for at least 30 minutes if recently driven to ensure all components are cool

Procedure

1. 1

   Access front fascia area
   Remove the front wheel well liner partial cover on the side being serviced. Remove approximately 5-6 push-pin retainers securing the front portion of the wheel well liner to access the rear of the headlight assembly. Use trim panel removal tools to avoid breaking retainers.
2. 2

   Remove front grille trim panel
   Remove the upper grille trim panel above the headlight assembly. Release the plastic clips by gently pulling outward starting from one end and working across. There are typically 4-6 clips securing this panel. Set panel aside in a safe location to avoid scratching.
3. 3

   Disconnect headlight electrical connectors
   Locate the main headlight connector at the rear of the assembly. Press the release tab and pull the connector straight back to disconnect. There may be multiple connectors for main beam, DRL, and turn signal functions. Mark or photograph connector positions for correct reinstallation.
4. 4

   Remove upper mounting bolts
   Using a 10mm socket, remove the two upper mounting bolts securing the headlight assembly to the front fascia support bracket. These bolts are accessed from the engine compartment area above the headlight. Keep bolts organized for reinstallation.
5. 5

   Remove lower mounting fastener
   Locate and remove the lower mounting fastener accessible from the wheel well area. This may be a 10mm bolt or T25 Torx screw depending on production date. Support the headlight assembly with one hand while removing this fastener.
6. 6

   Remove side mounting bolt
   Remove the side mounting bolt located on the inner fender area using a 10mm socket. This bolt secures the outboard side of the headlight assembly to the body. Access is typically through the wheel well opening.
7. 7

   Release headlight assembly from clips
   Gently pull the headlight assembly forward while checking for any remaining clips or fasteners. The assembly typically has 2-3 alignment pins that fit into grommets in the body. Rock the assembly gently side-to-side while pulling forward to release these pins. Support the weight of the assembly as it releases.
8. 8

   Remove headlight assembly
   Carefully maneuver the headlight assembly out of the vehicle, being cautious of surrounding painted surfaces. Tilt the assembly as needed to clear any obstructions. Place the removed assembly on a clean, soft surface with the lens facing up to prevent scratches.
9. 9

   Prepare new headlight assembly
   Unpack the new headlight assembly and inspect for any shipping damage. Remove all protective film and packaging materials. Apply a small amount of dielectric grease to all electrical connector terminals to prevent corrosion and ensure good electrical contact.
10. 10

    Install new headlight assembly
    Position the new headlight assembly at an angle and carefully guide it into the mounting location. Align the locating pins with their grommets in the body. Push firmly but gently to seat the assembly fully into position. Ensure all alignment pins are fully engaged before installing fasteners.
11. 11

    Install mounting fasteners
    Install the side mounting bolt first to hold the assembly in position, then install the upper two mounting bolts, followed by the lower mounting fastener. Hand-tighten all fasteners first, then torque in sequence starting from the top. Since torque specifications are not provided in the database, tighten fasteners snugly but do not over-torque plastic-threaded mounting points.
12. 12

    Reconnect electrical connectors
    Reconnect all electrical connectors to the headlight assembly in their correct positions as marked during removal. Each connector should click firmly into place. Verify that the locking tabs are fully engaged on all connectors.
13. 13

    Reinstall trim components
    Reinstall the front grille trim panel by aligning the clips and pressing firmly until all clips engage with an audible click. Reinstall the wheel well liner section and secure with push-pin retainers, replacing any damaged retainers with new ones.

Reassembly

1. Reconnect the 12V battery negative terminal
2. Verify all trim panels and fasteners are properly secured
3. Close hood and ensure it latches properly
4. Torque specifications not available in database - use standard practice for plastic and sheet metal fasteners on electric vehicles

Verification

• Turn vehicle to ON position and verify headlight operates correctly in all modes (low beam, high beam, DRL, turn signal)
• Check headlight aim and adjust if necessary using the headlight adjustment screws on the back of the assembly
• Inspect all trim panels for proper fit and secure attachment with no gaps or misalignment
• Verify no warning lights appear on the instrument cluster related to lighting systems
• Test all other lighting functions to ensure no connectors were disturbed during the repair
• Road test vehicle and verify headlight functions properly under normal driving conditions

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