This procedure covers the removal and replacement of both headlight bulb assemblies on the 2024 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• LED headlight bulb assembly - driver side × 1 — Use OEM specification
• LED headlight bulb assembly - passenger side × 1 — Use OEM specification
• Headlight bulb seal/gasket (if equipped) × 2 — Use OEM specification
• Push pin retainers (if damaged) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow electrical systems to cool
3. Open front hood and secure with prop rod
4. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
5. Wear nitrile gloves to prevent oil contamination on LED elements
6. Photograph existing headlight connections for reference during reassembly

Procedure

1. 1

   Access front bumper cover fasteners
   Remove the push pin retainers along the top edge of the front bumper cover above each headlight assembly. Use the trim panel removal tool to carefully pry the center pins up, then remove the entire retainer. There are typically 2 retainers per side above the headlight area.
2. 2

   Remove wheel well liner fasteners
   Turn the steering wheel to full lock (away from the side being serviced) to access the front wheel well liner. Remove the forward section fasteners using the T25 Torx bit. You only need to remove enough of the liner to access the side of the headlight assembly, approximately 3-4 fasteners per side.
3. 3

   Peel back wheel well liner
   Carefully peel back the front portion of the wheel well liner to expose the side access point to the headlight assembly. This will reveal the outer mounting bolt and electrical connector access.
4. 4

   Disconnect headlight electrical connector - driver side
   Locate the main headlight electrical connector behind the driver side headlight assembly. Press the locking tab and carefully disconnect the connector. If equipped with adaptive headlights, there may be a secondary connector for the leveling motor that must also be disconnected.
5. 5

   Remove headlight mounting bolts - driver side
   Remove the three 10mm mounting bolts securing the driver side headlight assembly. There is typically one accessible from the top under the hood, one from the wheel well side access, and one from the front near the grille area. Support the headlight assembly as you remove the final bolt.
   ⚠The headlight assembly is not firmly attached once the final bolt is removed. Support it to prevent dropping and damage.
6. 6

   Remove driver side headlight assembly
   Carefully pull the headlight assembly forward and out of the vehicle. It may require gentle wiggling to clear the alignment pins and surrounding body panels. Place the assembly on a clean, padded surface with the lens facing up.
7. 7

   Access and remove LED bulb module - driver side
   Locate the bulb access cover on the rear of the headlight assembly. Rotate the cover counterclockwise approximately 1/4 turn and remove. Disconnect the bulb connector if present, then rotate the LED bulb module counterclockwise and carefully extract it from the housing. Note the orientation and alignment tab position for installation.
   ⚠Do not touch the LED element or lens surfaces. Handle bulb module by the base only.
8. 8

   Install new LED bulb module - driver side
   Inspect the bulb seal/gasket and replace if damaged or hardened. Align the new LED bulb module with the alignment tab in the correct position and insert it into the housing. Rotate clockwise until it locks into place. Reconnect the bulb connector if applicable, then reinstall the access cover by rotating clockwise.
9. 9

   Reinstall driver side headlight assembly
   Carefully position the headlight assembly back into the vehicle, aligning it with the mounting points and alignment pins. Install all three 10mm mounting bolts and tighten in a cross pattern to ensure even seating. Reconnect all electrical connectors, ensuring the locking tabs click into place.
10. 10

    Repeat procedure for passenger side
    Perform steps 2 through 9 for the passenger side headlight assembly, following the same sequence: access wheel well liner, disconnect electrical connector, remove mounting bolts, remove assembly, replace bulb module, reinstall assembly, and reconnect electrical.
11. 11

    Reinstall wheel well liners
    Reposition both front wheel well liners and reinstall all T25 Torx fasteners that were removed. Ensure the liner is properly seated behind the bumper cover edge before tightening fasteners.
12. 12

    Reinstall bumper cover fasteners
    Reinstall all push pin retainers along the top edge of the front bumper cover. Push the retainer body into the hole first, then press the center pin down until it is flush with the retainer body to lock it in place.
13. 13

    Reconnect battery and initialize system
    Reconnect the 12V battery negative terminal. Turn the vehicle to the ON position (without starting) and allow the electrical system to initialize. This may take 2-3 minutes. Check for any warning lights related to the lighting system on the instrument cluster.

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify headlight assemblies are properly aligned and flush with surrounding body panels
3. Check that all trim panels and wheel well liners are securely fastened with no gaps
4. Confirm no tools or parts were left in the engine compartment or wheel wells

Verification

• Turn on headlights and verify both low beams illuminate properly with no flickering or error messages
• Activate high beams and verify both headlights switch to high beam mode correctly
• Test turn signals to ensure they function properly and are not affected by the headlight work
• If equipped, verify adaptive headlight leveling functions by observing beam adjustment when vehicle is turned on
• Perform a test drive and verify headlight aim is correct and no lights are loose or rattling
• Check for proper sealing by inspecting for any light leaks around the headlight assemblies in a dark environment

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