LED Headlight Module

This procedure covers the removal and replacement of the LED headlight module on a 2024 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification
• Headlight mounting hardware kit (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure high-voltage system is off and vehicle has been powered down for at least 5 minutes
3. Disconnect 12V auxiliary battery negative terminal located in front cargo area
4. Allow headlights to cool completely if vehicle was recently operated (minimum 30 minutes)
5. Photograph existing headlight module position and wiring routing for reference
6. Ensure replacement LED module is correct part number for vehicle trim level and configuration

Procedure

1. 1

   Access front fascia attachment points
   Open the front cargo hood. Remove the upper grille panel by releasing the clips along the top edge using a trim removal tool. Work from center outward to avoid breaking clips. There are approximately 8-10 clips securing the panel.
2. 2

   Remove wheel well liner section
   Turn the steering wheel to full lock (away from the side being serviced) to gain access to the front wheel well. Remove the front portion of the wheel well liner by removing the Torx fasteners (T25) and releasing the plastic clips. Fold the liner back to expose the rear headlight mounting access point.
3. 3

   Disconnect headlight electrical connectors
   Locate the headlight main connector and adaptive lighting connector (if equipped) behind the headlight assembly. Press the release tab on each connector and carefully pull straight back to disconnect. The main connector is a large multi-pin connector; ensure you support the connector body while releasing to avoid damaging pins.
4. 4

   Remove upper headlight mounting fasteners
   From the upper grille opening, locate and remove the two upper headlight mounting bolts using a 10mm socket. These bolts thread into the headlight housing from above. Keep track of any alignment shims or spacers that may be present.
5. 5

   Remove lower and side mounting fasteners
   Access the lower mounting bolt through the wheel well opening using a 10mm socket with extension. Remove the side mounting fastener (T30 Torx) accessible from the wheel well area. There are typically 3-4 mounting points total securing the headlight assembly.
6. 6

   Release headlight assembly from fender
   Gently pull the headlight assembly forward and outward from the fender. The assembly is located with alignment pins and may require light rocking motion to release. Do not force; check for any missed fasteners if significant resistance is encountered. Be aware of the weight of the assembly (approximately 8-10 lbs).
7. 7

   Remove LED module from housing (if applicable)
   If replacing only the LED module and not the complete assembly, place the headlight assembly on a clean, padded surface. Remove the rear access cover by rotating counterclockwise or releasing locking tabs. Remove the module retaining ring by rotating counterclockwise, then carefully extract the LED module from the housing. Note the orientation tab position.
8. 8

   Install new LED headlight module
   If installing module only: Insert the new LED module into the housing, aligning the orientation tab. Install and rotate the retaining ring clockwise until it locks. Replace the rear access cover. If installing complete assembly: Verify all seals and gaskets are present on the new assembly and ensure protective coverings are removed from lens.
9. 9

   Position headlight assembly
   Carefully align the headlight assembly with the fender mounting points and alignment pins. Ensure wiring harness is properly routed and not pinched. Push the assembly rearward until it seats against the fender. Verify alignment with adjacent body panels before installing fasteners.
10. 10

    Install mounting fasteners
    Install all mounting bolts and fasteners hand-tight first to ensure proper alignment. Once all fasteners are started, tighten in sequence: upper bolts first, then side fastener, then lower bolt. Tighten fasteners securely but do not over-torque as headlight housing is composite material.
11. 11

    Reconnect electrical connectors
    Reconnect the headlight electrical connectors, ensuring each connector clicks fully into place. Verify that connector locks are engaged and seals are properly seated. Route wiring harness to match original routing documented in preparation photos.
12. 12

    Reinstall wheel well liner and grille panel
    Reposition the wheel well liner and install all Torx fasteners and clips. Ensure liner is fully seated before securing. Reinstall the upper grille panel by aligning the clips and pressing firmly until each clip engages with an audible click.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Verify all trim panels and fasteners are properly secured
3. Close front cargo hood and ensure proper latch engagement
4. Return steering wheel to center position

Verification

• Power on the vehicle and activate all headlight functions: low beam, high beam, daytime running lights, and turn signals
• Verify adaptive lighting functions operate correctly if vehicle is equipped (steering-responsive headlights)
• Check for any warning messages on the instrument cluster related to lighting systems
• Inspect headlight assembly fitment and panel gaps around the entire perimeter
• Perform headlight aim check using a headlight aiming tool or alignment screen at 25 feet, adjust as necessary using the adjustment screws accessed from the engine bay
• Test headlight leveling system if equipped by loading vehicle and verifying automatic adjustment
• Perform a test drive to ensure no vibration or movement of the headlight assembly

Related trouble codes on this vehicle

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