Replace a single headlight bulb assembly on the 2024 Rivian EDV 500 electric delivery van, requiring removal of front fascia components and headlight housing.

Warnings

Tools required

Parts

• LED headlight bulb assembly × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and remove key fob from vehicle proximity to ensure vehicle is completely powered down
3. Allow headlights to cool for at least 15 minutes if recently operated
4. Open hood and secure with prop rod
5. Photograph headlight assembly orientation and connector positions for reference during reassembly

Procedure

1. 1

   Disconnect 12V battery
   Locate the 12V auxiliary battery in the front cargo area. Using a 10mm socket, loosen and remove the negative terminal cable first, then the positive terminal. Secure cables away from battery posts to prevent accidental reconnection. Wait 5 minutes for vehicle systems to fully power down.
2. 2

   Remove front wheel well liner (partial)
   Turn steering wheel fully to the opposite side of the headlight being replaced for access. Remove the front portion of the wheel well liner using trim panel removal tools to release plastic clips. Remove approximately 6-8 clips along the front edge. Fold liner back to expose headlight housing access from the side.
3. 3

   Remove front bumper fascia clips
   Locate and remove the plastic clips securing the top edge of the front bumper fascia to the hood support structure. There are typically 8-10 clips along the top edge. Use trim panel removal tool to pry clips straight up. Store clips in magnetic tray as they will be reused.
4. 4

   Remove grille assembly fasteners
   Using T25 Torx driver, remove the fasteners securing the grille assembly (typically 4-6 fasteners). Gently pull the top of the grille forward to create access space to the headlight housing. The grille does not need to be completely removed, just loosened enough to access headlight mounting bolts.
5. 5

   Disconnect headlight electrical connectors
   Reach behind the headlight housing and locate the main electrical connector. Press the locking tab and pull connector straight back to disconnect. There may be 2-3 connectors depending on configuration (main headlight, DRL, and position light). Label connectors with tape if necessary to ensure correct reconnection.
6. 6

   Remove headlight housing mounting bolts
   Using T25 Torx driver, remove the three mounting bolts securing the headlight housing to the vehicle body. One bolt is typically located at the top center, one at the outer top corner, and one at the lower inner position. Support the headlight housing with one hand while removing the final bolt.
7. 7

   Extract headlight assembly
   Carefully pull the headlight housing forward and outward from the mounting position. There may be alignment pins that require wiggling the housing slightly. Once clear of mounting pins, rotate the housing as needed to maneuver it out through the access space created by the loosened grille. Be careful not to scratch adjacent painted surfaces.
8. 8

   Remove bulb assembly from housing
   Place headlight housing on clean, protected work surface with lens facing down. Locate the bulb retaining collar or locking ring on the back of the housing. Rotate the collar counterclockwise (typically 1/4 turn) to unlock. Carefully extract the failed LED bulb assembly from the housing. Note the orientation of alignment tabs for new bulb installation.
9. 9

   Install new LED bulb assembly
   Wearing nitrile gloves, remove new LED bulb assembly from packaging handling only by the base. Align the tabs on the bulb base with slots in the housing and insert fully until seated. Rotate the locking collar clockwise 1/4 turn until it clicks and locks. Verify the bulb is firmly secured and cannot rotate.
10. 10

    Reinstall headlight housing
    Maneuver the headlight housing back into position, aligning the mounting holes and locating pins with the vehicle body. Push the housing fully into place ensuring it sits flush with surrounding body panels. Install the three T25 Torx mounting bolts and tighten evenly in a star pattern. Ensure housing is properly aligned before final tightening.
11. 11

    Reconnect electrical connectors
    Reconnect all electrical connectors to the headlight assembly, pressing firmly until each connector clicks into place. Gently tug on each connector to verify secure connection. Refer to photos taken during disassembly if needed to ensure correct connector positions.
12. 12

    Reinstall grille and fascia components
    Reposition the grille assembly and install all T25 Torx fasteners, tightening securely. Reinstall all bumper fascia clips along the top edge, pressing firmly until each clip seats with an audible click. Verify all clips are fully engaged and fascia is properly aligned with hood and fender gaps.
13. 13

    Reinstall wheel well liner
    Fold the wheel well liner back into position and reinstall all plastic clips along the front edge. Ensure liner is properly seated behind the bumper fascia edge. Verify all clips are secure and liner does not interfere with wheel movement through full steering range.
14. 14

    Reconnect 12V battery
    Reconnect the 12V auxiliary battery, connecting the positive terminal first, then the negative terminal. Tighten both terminals securely with 10mm socket. The vehicle will perform a brief system initialization when power is restored.

Reassembly

1. Verify all trim panels and fascia components are properly aligned with even gaps before final testing
2. Ensure no tools or parts have been left in the engine compartment or wheel well area
3. Check that all removed fasteners have been reinstalled and accounted for

Verification

• With vehicle powered on, activate headlights and verify both low beam and high beam function correctly on the repaired side
• Check that DRL (daytime running light) and position light functions operate correctly
• Verify headlight aim appears correct and matches the opposite side; professional aim adjustment may be required
• Inspect all reinstalled trim components for proper fit and secure attachment
• Test drive vehicle and verify no warning lights appear on instrument cluster related to lighting system
• Verify no water intrusion points exist where fascia components were removed and reinstalled

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