Replace a single headlight bulb assembly on the 2023 Rivian EDV 500 electric delivery van, requiring front fascia and headlight module removal.

Warnings

Tools required

Parts

• LED headlight bulb module × 1 — Use OEM Rivian specification
• Headlight module seal/gasket × 1 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure headlights have been off for at least 30 minutes to allow cooling
3. Disconnect 12V battery negative terminal located in front compartment
4. Open front hood/access panel to access headlight mounting area
5. Photograph headlight electrical connector orientation before removal

Procedure

1. 1

   Remove front fascia lower section
   Using T25 Torx bit, remove the lower fascia screws along the bottom edge. There are typically 6-8 screws securing the lower section. Use plastic trim tools to carefully release the clips along the wheel well edges on the affected side.
2. 2

   Remove wheel well liner fasteners
   Turn the steering wheel fully to the opposite side of the headlight being replaced for access. Remove the T25 Torx screws and plastic push pins securing the front portion of the wheel well liner. Fold back the liner to expose the side of the headlight assembly.
3. 3

   Disconnect headlight electrical connector
   Locate the main headlight electrical connector behind the headlight assembly. Press the locking tab and carefully pull the connector straight back. If equipped with active leveling, disconnect the secondary leveling motor connector as well.
4. 4

   Remove headlight assembly mounting bolts
   Using T30 Torx bit and 10mm socket, remove the headlight assembly mounting bolts. There are typically three bolts: one accessible from the top near the hood opening, one from the side through the wheel well, and one from behind near the radiator support. Keep bolts organized for reinstallation.
5. 5

   Extract headlight assembly
   Carefully pull the headlight assembly forward and out of the mounting pocket. Work slowly to avoid catching on any remaining clips or brackets. The assembly should slide forward once all fasteners are removed. Place assembly on clean, padded work surface.
6. 6

   Remove headlight bulb module access cover
   On the rear of the headlight assembly, locate the circular or rectangular access cover for the bulb module. Rotate counterclockwise approximately 1/4 turn or release locking tabs depending on design. Remove the access cover to expose the bulb module.
7. 7

   Release bulb module retention mechanism
   Identify the retention clip or twist-lock mechanism securing the LED bulb module. For twist-lock style, rotate the module counterclockwise 1/4 turn. For clip style, compress the spring clip and pivot it out of the way. Do not force - mechanism should release with moderate pressure.
8. 8

   Remove failed bulb module
   Carefully pull the LED bulb module straight out from the reflector housing. Note the orientation of alignment tabs. Inspect the module seal/gasket for damage or deterioration. If seal is damaged, replace it before installing new module.
9. 9

   Install new bulb module
   Insert the new LED bulb module into the reflector housing, aligning the tabs with their corresponding slots. Ensure the module seats fully - you should feel it bottom out gently. Do not touch LED surfaces or gold electrical contacts with bare hands.
10. 10

    Secure bulb module retention
    Engage the retention clip or rotate the twist-lock mechanism clockwise 1/4 turn until it locks. Verify the module is firmly secured and cannot be pulled out. Reinstall the access cover, rotating clockwise or engaging tabs until it locks.
11. 11

    Reinstall headlight assembly
    Guide the headlight assembly back into the mounting pocket, ensuring all alignment pins engage properly. Take care not to pinch any wiring. Push assembly flush with surrounding body panels before installing fasteners.
12. 12

    Reinstall mounting hardware and connections
    Install and tighten the three mounting bolts using T30 Torx bit and 10mm socket. Tighten in a cross pattern to ensure even seating. Reconnect the main electrical connector and any secondary connectors until they click into place.
13. 13

    Reinstall wheel well liner and fascia
    Reposition the wheel well liner and secure with all T25 screws and push pins. Align the front fascia lower section and press firmly to engage all clips. Install all fascia mounting screws and verify all clips are properly seated.

Reassembly

1. Reconnect 12V battery negative terminal
2. Verify all trim pieces and panels are properly secured with no gaps
3. Ensure all electrical connectors are fully seated and locked
4. Check that headlight assembly is flush with adjacent body panels

Verification

• Turn ignition to ON position and activate headlights - verify new bulb illuminates properly
• Test all headlight functions: low beam, high beam, and turn signal if integrated
• Check for proper headlight aim - adjust if necessary using adjustment screws
• Verify no warning lights on instrument cluster related to headlight system
• Inspect all reinstalled trim pieces for proper fit and secure mounting
• Take short test drive and verify headlight performance under normal conditions

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