This procedure covers the removal and replacement of the headlight assembly on a 2024 Rivian EDV 500 electric delivery van, including disconnecting electrical connectors and mounting hardware.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification
• Push-in retainer clips (if damaged) × 5 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and electrical systems
3. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Ensure headlight assembly is cool to the touch if vehicle was recently operated
5. Place fender cover over front fender to protect paint
6. Take photos of headlight position and wiring connections for reference during reassembly

Procedure

1. 1

   Access front bumper cover fasteners
   Open the front hood. Locate and remove the upper grille panel push-in fasteners using the trim removal tool. There are typically 6-8 fasteners along the top edge of the grille. Carefully pull the grille panel forward to release it from the lower clips.
2. 2

   Remove front wheel well liner section
   Turn the steering wheel fully to expose the front wheel well on the side being serviced. Remove the three Torx T30 screws securing the forward section of the wheel well liner. Fold back the liner to access the side mounting area of the headlight assembly.
3. 3

   Disconnect headlight electrical connectors
   Locate the main headlight connector behind the assembly. Press the locking tab and carefully pull the connector straight back to disconnect. If equipped with adaptive headlights, disconnect the secondary connector for the leveling motor. Label connectors if necessary for identification during reassembly.
4. 4

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

   Remove lower and side mounting fasteners
   From the wheel well opening, locate and remove the lower 10mm mounting bolt. Remove the side mounting bolt accessible through the wheel well. Some fasteners may be Torx T30 screws depending on production date.
6. 6

   Release headlight assembly from bumper cover
   Gently pull the outer edge of the headlight assembly forward while supporting its weight. The assembly has alignment pins that fit into the bumper cover and front structure. Carefully work the assembly free from these locating pins without forcing.
7. 7

   Remove headlight assembly
   Once all fasteners are removed and the assembly is free from locating pins, carefully lift and pull the headlight assembly forward and out of the vehicle. Be mindful of the weight and avoid hitting surrounding body panels. Set the old assembly aside on a protected surface.
8. 8

   Inspect mounting points and clean area
   Inspect all mounting points for damage, corrosion, or stripped threads. Check the alignment pins on the vehicle for any damage. Clean the mounting surface area with a clean cloth to remove dirt and debris. Verify all grounding points are clean and free of corrosion.
9. 9

   Prepare new headlight assembly
   Remove the new headlight assembly from packaging carefully. Verify it matches the original unit and all mounting points align. If the assembly includes protective film, remove it from the lens. Do not touch the lens with bare hands to avoid fingerprints.
10. 10

    Install new headlight assembly
    Carefully guide the new headlight assembly into position, aligning the locating pins with their receptacles in the bumper cover and support structure. Support the weight of the assembly while ensuring proper alignment before installing fasteners.
11. 11

    Install mounting fasteners
    Install and hand-tighten all mounting bolts in this order: upper two bolts first, then lower bolt, then side bolt. Once all fasteners are started, tighten them in a cross pattern to the manufacturer's specification. Since specific torque values are not available, tighten fasteners snugly without over-tightening (approximately 10-15 ft-lbs).
12. 12

    Reconnect electrical connectors
    Reconnect the main headlight electrical connector, ensuring it clicks into place and the locking tab engages. If equipped with adaptive headlights, reconnect the leveling motor connector. Gently tug on connectors to verify secure connection.
13. 13

    Reinstall wheel well liner and grille
    Reposition the wheel well liner and install the three Torx T30 screws. Align the upper grille panel and press firmly to engage the lower clips. Install the upper push-in fasteners to secure the grille panel.
14. 14

    Reconnect battery and test
    Reconnect the 12V battery negative terminal. Turn on the vehicle's electrical system without starting the drive system. Test all headlight functions including low beam, high beam, turn signals, and daytime running lights. Check for proper operation and verify no warning messages appear on the instrument cluster.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all mounting bolts are tightened in a cross pattern to prevent misalignment
3. Check that wheel well liner is properly secured and not rubbing on tire
4. Confirm all trim panels and grille pieces are fully seated with no gaps

Verification

• Test all headlight functions with vehicle electrical system on: low beam, high beam, turn signals, DRL, and parking lights
• Visually inspect headlight alignment by comparing beam pattern to the opposite side
• Check for proper headlight seating with uniform gaps around the assembly
• Verify no warning lights or error messages are displayed on the instrument cluster
• Schedule headlight aiming adjustment if beam pattern appears misaligned
• Test adaptive headlight function (if equipped) by turning steering wheel lock to lock with lights on

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