This procedure covers the removal and replacement of both headlight assemblies on a 2025 Rivian EDV 500 commercial delivery van, including electrical connector disconnection and mounting hardware removal.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification
• Right headlight assembly × 1 — Use OEM specification
• Headlight mounting fasteners (if damaged) × 1 — Use OEM specification
• Push pin retainers for wheel well liner × 4 — Use OEM specification

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Turn off all vehicle systems and remove key fob from vehicle proximity
3. Open hood and secure in the open position
4. Disconnect the 12V battery negative terminal and isolate the cable
5. Wait at least 2 minutes for electrical systems to discharge
6. If working on driver side, turn steering wheel to full right. If working on passenger side, turn to full left for access
7. Use masking tape to protect adjacent painted surfaces from scratches

Procedure

1. 1

   Remove front wheel well liner access section
   Turn the front wheel outward for the side being serviced. Locate the push pin retainers securing the forward section of the wheel well liner. Use a trim clip removal tool to remove 3-5 push pins along the front edge of the liner. Pull the liner back to access the rear of the headlight assembly. You may need to remove the entire liner on some sides depending on access.
2. 2

   Remove front fascia upper trim clips
   Open the hood fully. Locate the plastic clips securing the upper edge of the front fascia to the hood latch support structure. Use a panel removal tool to carefully release 2-3 clips directly above the headlight assembly being serviced. Pull the fascia edge away slightly to provide clearance for headlight removal.
3. 3

   Disconnect headlight electrical connectors
   Reach behind the headlight assembly from the wheel well opening. Locate the main headlight connector (large multi-pin connector). Press the locking tab and pull the connector straight back to disconnect. Locate the secondary connector for the daytime running light or auxiliary lighting if equipped. Press its release tab and disconnect. Ensure no wiring is caught or binding.
4. 4

   Remove upper headlight mounting fasteners
   From the engine compartment, locate the two upper mounting fasteners securing the top of the headlight assembly. These are typically T30 Torx bolts. Remove both upper mounting bolts completely and store them in a safe location. Note the presence of any alignment shims or spacers and keep them with the corresponding bolt.
5. 5

   Remove lower headlight mounting fastener
   From the wheel well opening, locate the lower mounting fastener at the bottom corner of the headlight assembly. This is typically a 10mm bolt or T25 Torx fastener. Remove the lower mounting fastener completely. Check for any additional side-mounted fasteners that may secure the outboard edge of the assembly.
6. 6

   Release headlight assembly retaining clips
   Identify any spring clips or plastic locking tabs that secure the headlight to the body panel. These are typically located along the inboard edge toward the grille. Use a panel tool to gently press the release tabs while applying slight outward pressure on the headlight assembly. Work carefully to avoid breaking clips.
7. 7

   Remove headlight assembly
   With all fasteners and clips released, carefully pull the headlight assembly forward and outward from the vehicle. Angle the assembly as needed to clear any mounting tabs or body panel edges. Inspect the mounting points on the vehicle for damage or missing hardware. Set the old headlight aside in a safe location on a clean, padded surface.
8. 8

   Prepare new headlight assembly
   Remove the new headlight assembly from its protective packaging. Inspect for any shipping damage or missing components. Compare the new assembly to the old unit to confirm correct part. Transfer any adjustment mechanisms or mounting hardware from the old unit if they are not included with the new assembly.
9. 9

   Install new headlight assembly
   Position the new headlight assembly at the mounting location. Angle the assembly to align the locating tabs with their corresponding slots in the body panel. Carefully guide the assembly into position, ensuring the mounting tabs engage properly. Press firmly but evenly to seat the assembly against the mounting surface.
10. 10

    Install lower mounting fastener
    From the wheel well opening, install the lower mounting fastener through the headlight assembly bracket into the body panel mounting point. Thread the fastener by hand first to ensure proper alignment. Tighten securely but do not overtighten to avoid cracking the mounting bracket.
11. 11

    Install upper mounting fasteners
    From the engine compartment, install the two upper mounting bolts along with any alignment shims or spacers in their original positions. Thread both bolts by hand to ensure proper thread engagement. Tighten the upper mounting bolts securely, alternating between the two to maintain even pressure on the assembly.
12. 12

    Reconnect electrical connectors
    Reach behind the headlight assembly and locate the electrical connectors. Align the main headlight connector and press firmly until you hear and feel a positive click indicating the locking tab has engaged. Connect the secondary connector for auxiliary lighting if equipped. Verify both connectors are fully seated and locked.
13. 13

    Reinstall front fascia trim and wheel well liner
    Push the front fascia upper edge back into position and reinstall the plastic retaining clips. Ensure the fascia is properly aligned with the headlight assembly edge. Pull the wheel well liner back into position and install new push pin retainers in all locations. Ensure the liner is secure and not rubbing against any moving components.
14. 14

    Repeat procedure for opposite side
    If replacing both headlight assemblies, repeat steps 1 through 13 for the opposite side of the vehicle. Maintain consistency with fastener tightness and connector seating on both sides.

Reassembly

1. Reconnect the 12V battery negative terminal
2. Verify all panel clips and fasteners are secure and no tools or parts remain in the engine compartment
3. Check that wheel well liners are properly secured and not contacting tires or steering components
4. Close hood and verify proper latch engagement

Verification

• Turn the vehicle to ON mode (do not start) and verify both headlight assemblies illuminate properly in low beam mode
• Activate high beams and verify both headlights switch to high beam function
• Test daytime running lights, turn signals, and any auxiliary lighting integrated into the headlight assemblies
• Check for proper headlight alignment by observing beam pattern on a flat surface or wall 25 feet away. Headlights should be level and aimed appropriately
• Perform a visual inspection to ensure headlight assemblies are flush with surrounding body panels and all gaps are even
• Check for any warning messages or fault codes related to lighting systems using the vehicle display
• If headlight aim is significantly off, headlight aiming adjustment will be required using the adjustment screws accessible from the engine compartment

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