Remove and replace the LED headlight module on a 2023 Rivian EDV 500, including proper disconnection of electrical connectors and mounting hardware.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification
• Headlight module seal/gasket × 1 — Use OEM specification (if not included with module)

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Power off the vehicle completely using the center display
3. Disconnect the 12V battery negative terminal and wait 10 minutes for system capacitors to discharge
4. Open the hood and secure it in the fully open position
5. Allow headlights to cool completely if recently operated (minimum 30 minutes)

Procedure

1. 1

   Remove front wheel well liner clips
   Turn the steering wheel fully to access the wheel well liner on the side being serviced. Remove the plastic clips securing the front portion of the wheel well liner to expose the rear of the headlight assembly. You will need to peel back approximately 12 inches of the liner for access.
2. 2

   Remove front fascia access panel
   Locate the access panel behind the headlight assembly in the front fascia area. Remove the T25 Torx screws (typically 3-4 screws) securing the access panel. Carefully pull the panel away from the vehicle to expose the headlight mounting area.
3. 3

   Disconnect headlight electrical connector
   Locate the main electrical connector at the rear of the headlight module. Press the locking tab on the connector and carefully pull it straight back from the headlight module. If equipped with adaptive headlights, there may be a secondary connector for the leveling motor that must also be disconnected.
4. 4

   Remove upper headlight mounting bolts
   Locate and remove the two 10mm bolts securing the top of the headlight module to the front body structure. These bolts are accessed from above with the hood open. Keep these bolts organized as they may have different lengths.
   ℹ️Support the headlight assembly with one hand while removing the final mounting bolts to prevent it from falling.
5. 5

   Remove lower headlight mounting bolt
   Access the lower mounting bolt through the wheel well opening. Remove the single 10mm bolt securing the bottom of the headlight module. This bolt may also secure a ground wire that must be retained for reassembly.
6. 6

   Remove outer headlight mounting fastener
   Locate the outer mounting point at the fender-side edge of the headlight assembly. Remove the T25 Torx screw or 10mm bolt securing this location. This fastener is typically accessed from the front fascia access opening.
7. 7

   Release headlight module from clips
   Carefully pull the headlight module forward and outward from the vehicle. The module is retained by alignment pins and clips at the inner edge. You may need to gently rock the assembly while pulling to disengage the clips. Be careful not to scratch the painted surfaces.
8. 8

   Inspect mounting points and clean surfaces
   With the headlight removed, inspect all mounting points, alignment pins, and the body structure for damage or corrosion. Clean the mounting surface and seal area with a clean cloth. Remove any old gasket material if present. Inspect the electrical connector on the vehicle harness for corrosion or damage.
9. 9

   Prepare new headlight module
   Remove the new LED headlight module from its packaging. Verify that all mounting points and alignment features match the original. If a new seal or gasket is provided, install it onto the headlight module per manufacturer instructions. Apply a thin coat of dielectric grease to the electrical connector pins if desired.
10. 10

    Install headlight module
    Align the headlight module with the mounting points and alignment pins on the vehicle body. Carefully slide the module into position, ensuring the inner clips engage properly. Press firmly until the module seats flush against the body structure. Verify that all gaps around the headlight are even before installing fasteners.
11. 11

    Install all mounting fasteners
    Install and hand-tighten all mounting bolts and screws in this sequence: upper bolts first, then outer fastener, then lower bolt. Tighten the upper 10mm bolts snugly but do not overtighten. Tighten the lower bolt and reattach any ground wires. Tighten the outer Torx screw. Ensure the headlight module sits flush and aligned with surrounding body panels.
12. 12

    Reconnect electrical connectors
    Connect the main electrical connector to the headlight module, ensuring it clicks into place securely. If equipped, reconnect the adaptive headlight leveling motor connector. Gently tug on each connector to verify proper engagement.
13. 13

    Reinstall access panels
    Reinstall the front fascia access panel and secure it with the T25 Torx screws. Reposition the wheel well liner and reinstall all clips, ensuring the liner is properly seated and not interfering with any moving components.
14. 14

    Reconnect battery and initialize system
    Reconnect the 12V battery negative terminal. Power on the vehicle using the center display. The system may display a headlight service message that should clear after successful operation. If equipped with adaptive headlights, the system may require initialization through the vehicle settings menu.

Reassembly

1. Ensure all electrical connectors are fully seated and locked before powering on the vehicle
2. Verify all body panels and access covers are properly secured with no missing fasteners
3. Check headlight alignment visually before driving; professional alignment may be required if aim is significantly off

Verification

• Power on the vehicle and verify no warning lights related to headlight system appear on the instrument cluster
• Test all headlight functions: low beam, high beam, and turn signals operate correctly
• Verify daytime running lights function properly
• If equipped, test adaptive headlight movement through vehicle settings menu
• Inspect the headlight module for proper seating with even gaps around all edges
• Test drive in a safe area after dark to verify proper light output and aim; adjust if necessary

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