This procedure covers the removal and replacement of the headlight assembly on a 2025 Rivian EDV 500 commercial delivery van, including electrical connector disconnection and front fascia access.

Warnings

Tools required

Parts

• Headlight assembly × 1 — Use OEM Rivian part number for EDV 500
• Headlight mounting hardware kit (if damaged) × 1 — Use OEM specification
• Electrical connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn off all vehicle systems and remove key fob from vehicle interior
3. Open hood and secure with prop rod
4. Disconnect 12V battery negative terminal located in front storage compartment
5. Wait minimum 5 minutes for electrical system capacitor discharge
6. Cover front fender area with protective material to prevent damage during repair
7. Take photo of headlight connector orientation before removal for reference

Procedure

1. 1

   Access front fascia fasteners
   Remove the front fascia upper grille panel by releasing the plastic clips along the top edge. Use trim panel removal tools to carefully pry the panel forward starting from the outer edges. There are approximately 8-10 clips securing this panel. Store clips in magnetic tray to prevent loss.
2. 2

   Remove wheel well liner access panel
   Turn steering wheel to full lock position (away from working side) to access the front wheel well liner. Remove the T30 Torx screws securing the front portion of the wheel well liner. Only partial removal is necessary - create enough access to reach behind the headlight assembly. Typically 3-4 screws need removal.
3. 3

   Disconnect headlight electrical connectors
   Locate the main headlight connector behind the headlight assembly accessible from the wheel well or engine compartment. Press the connector release tab and carefully pull the connector straight back from the headlight housing. There are typically 2-3 connectors per assembly: main lighting harness, adaptive lighting module (if equipped), and daytime running light connector. Label each connector position if working on both sides.
4. 4

   Remove headlight upper mounting bolts
   From the engine compartment, locate and remove the two upper 10mm mounting bolts securing the top of the headlight assembly to the front fascia support bracket. These bolts are accessed from above the headlight unit. Support the headlight with one hand while removing the final bolt to prevent it from falling.
5. 5

   Remove headlight lower mounting fasteners
   From the wheel well access area, locate and remove the lower mounting fastener(s) securing the bottom of the headlight assembly. This is typically one 10mm bolt or T30 Torx screw. The lower mount may also have a positioning tab that slides into a bracket - note the orientation for reassembly.
6. 6

   Remove headlight outer mounting point
   Locate the outer mounting point near the fender edge. This is typically a 10mm bolt or T30 Torx screw accessible from the front. Remove this fastener while continuing to support the headlight assembly.
7. 7

   Release headlight assembly from vehicle
   With all mounting points removed, carefully pull the headlight assembly forward and outward from the vehicle. The assembly may have alignment pins or tabs that require slight angling during removal. Guide the assembly carefully to avoid scratching the paint or breaking mounting tabs. The unit may need to be tilted or rotated slightly to clear the fascia opening.
8. 8

   Inspect mounting points and clean installation area
   Examine all mounting brackets, alignment pins, and the vehicle mounting surface for damage, corrosion, or debris. Clean the mounting surface with a lint-free cloth. Check that all rubber seals or grommets are in good condition. Replace any damaged hardware before installing the new assembly.
9. 9

   Install new headlight assembly
   Position the new headlight assembly near the mounting opening. Align the lower positioning tabs first, then guide the assembly into position while ensuring electrical connector access points are properly oriented. Insert the assembly at the same angle used during removal. Seat the assembly fully against the mounting surface, verifying all alignment pins are properly engaged.
10. 10

    Install mounting fasteners
    Install and hand-tighten all mounting bolts in this sequence: lower mount first, then outer mount, then upper mounts. This ensures proper alignment. Tighten fasteners progressively and evenly. Do not fully torque one bolt before starting others. Verify the headlight sits flush with surrounding body panels and gaps are even on all sides.
11. 11

    Reconnect electrical connectors
    Reconnect all headlight electrical connectors in their original positions, referencing photos taken during disassembly. Push each connector firmly until the locking tab clicks into place. Gently tug on each connector to verify secure connection. Ensure no wires are pinched or under tension.
12. 12

    Reinstall wheel well liner and fascia panels
    Reposition the wheel well liner and install the T30 Torx screws removed earlier. Reinstall the front fascia grille panel by aligning the clips and pressing firmly until all clips engage. Verify all panels are flush and properly seated.
13. 13

    Reconnect battery and perform system check
    Reconnect the 12V battery negative terminal in the front storage compartment. Enter the vehicle and cycle the headlight switch through all positions (off, parking lights, low beam, high beam). Test turn signals and daytime running lights if equipped. Check for any warning messages on the instrument cluster.

Reassembly

1. Tighten all fasteners in proper sequence to ensure even pressure and correct alignment
2. Verify all electrical connectors are fully seated with locking tabs engaged
3. Confirm headlight assembly sits flush with body panels with even gap spacing
4. Ensure no wires are pinched between headlight assembly and mounting points
5. Double-check that all trim panels and wheel well liner sections are properly secured

Verification

• Test all headlight functions: low beam, high beam, daytime running lights, and turn signals
• Verify no warning lights appear on instrument cluster related to exterior lighting
• Inspect headlight assembly from outside vehicle to confirm proper seating and even gaps
• Check that headlight beam pattern appears normal and aimed correctly (professional alignment recommended)
• Verify adaptive headlight functions operate correctly if vehicle is so equipped
• Confirm all fascia panels and wheel well liner sections are secure with no loose clips or fasteners

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