This procedure replaces both headlight bulb assemblies on the 2023 Rivian EDV 500 electric delivery van, requiring partial front fascia and bumper component removal to access the headlight assemblies.

Warnings

Tools required

Parts

• Driver side headlight assembly × 1 — Rivian OEM headlight assembly - left
• Passenger side headlight assembly × 1 — Rivian OEM headlight assembly - right
• Push pin retainers × 10 — Replace any damaged clips during removal

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. Allow vehicle to sit for 5 minutes to ensure all systems are powered down
4. Open hood and secure with prop rod
5. Disconnect 12V battery negative terminal located in front trunk compartment
6. Wait 10 minutes after battery disconnect for capacitor discharge
7. Verify headlights are completely cool to the touch if recently operated

Procedure

1. 1

   Remove front grille upper trim panel
   Using trim panel tools, carefully release the plastic clips securing the upper grille trim panel. There are 6 clips along the top edge. Lift panel upward and away from vehicle once all clips are released. Set aside in safe location.
2. 2

   Remove wheel well liner access panels
   On the side being serviced, turn front wheels to full opposite lock for access. Remove 4 T25 Torx screws securing the front portion of the wheel well liner. Fold liner back to expose rear of headlight assembly. Repeat for opposite side if replacing both assemblies.
3. 3

   Disconnect headlight electrical connectors
   Reach behind headlight assembly and locate the main electrical connector. Press release tab and pull connector straight back from headlight assembly. Note connector orientation for reinstallation. There is one main connector per headlight assembly with integrated pins for low beam, high beam, DRL, and turn signal LEDs.
4. 4

   Remove headlight assembly mounting bolts
   Locate three 10mm mounting bolts securing headlight assembly: one at top center, one at outer edge near fender, and one accessible from wheel well area at lower rear. Remove all three bolts completely and retain for reinstallation. Support headlight assembly while removing final bolt.
   ⚠Headlight assembly weighs approximately 8 pounds. Support assembly to prevent dropping when final bolt is removed.
5. 5

   Release headlight positioning tabs
   With mounting bolts removed, gently pull headlight assembly forward while observing alignment tabs at top and bottom. The assembly slides forward on two guide pins. Work assembly forward approximately 2 inches until it clears mounting pins, then lift away from vehicle.
6. 6

   Inspect mounting points and clean
   Examine mounting bracket area for debris, corrosion, or damage. Clean mounting surfaces with dry cloth. Inspect rubber sealing gasket on vehicle body for damage or deterioration. Verify guide pins are straight and not bent.
7. 7

   Prepare new headlight assembly
   Remove new headlight assembly from protective packaging. Inspect for shipping damage. Verify rubber gasket is properly seated in assembly perimeter groove. Do not remove protective film from lens if present until after installation is complete.
8. 8

   Install new headlight assembly
   Align new assembly with guide pins on vehicle body. Slide assembly rearward onto pins until it seats flush against mounting surface. Ensure top and bottom alignment tabs engage properly. Assembly should sit uniformly with consistent gaps around perimeter matching opposite side.
9. 9

   Install mounting bolts
   Thread all three 10mm mounting bolts by hand first to ensure proper alignment. Tighten in sequence: top center first, then outer fender bolt, finally lower rear bolt. Tighten to snug specification - do not overtighten as this can crack assembly housing. Verify assembly does not move when gently pulled.
10. 10

    Connect electrical connector
    Align electrical connector with headlight assembly socket, matching key orientation. Press firmly until connector clicks into locked position. Gently tug connector to verify secure latch engagement. Ensure no wires are pinched or stressed.
11. 11

    Reinstall wheel well liner
    Position wheel well liner to original position. Install 4 T25 Torx screws in reverse order of removal. Ensure liner sits flush and does not interfere with tire rotation. Return wheels to straight position.
12. 12

    Reinstall grille trim panel
    Align upper grille trim panel with mounting locations. Press firmly at each clip location until all 6 clips snap into place. Verify panel is secure and aligned properly with adjacent panels.
13. 13

    Repeat for opposite side
    If replacing both headlight assemblies, repeat steps 2 through 12 for the opposite side of vehicle. Ensure both assemblies are installed symmetrically with matching gaps and alignment.
14. 14

    Reconnect battery and initialize
    Reconnect 12V battery negative terminal. Ensure connection is clean and tight. The vehicle may require several minutes to complete system checks after battery reconnection. Headlight aim may need calibration through vehicle settings menu.

Reassembly

1. Remove any protective film from headlight lenses if present
2. Verify all trim panels and fasteners are properly secured
3. Check that no tools or parts were left in engine bay or wheel wells
4. Close hood and verify proper latch engagement

Verification

• Turn ignition to ON position without starting vehicle
• Test low beam headlights - both should illuminate with proper intensity
• Test high beam headlights - both should illuminate brighter than low beams
• Test daytime running lights if equipped
• Test turn signals on both sides - should flash at normal rate without hyper-flash
• Verify no warning lights on instrument cluster related to exterior lighting
• Inspect headlight assemblies from outside vehicle for proper seating and alignment with body panels
• Check for even light output pattern on both sides by observing against wall or garage door from 25 feet
• If headlight aim warning appears on dash, calibration through dealer service mode may be required

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