This procedure covers the replacement of a single headlight bulb assembly on the 2025 Rivian EDV 500, which requires removal of the front bumper fascia and headlight assembly due to the sealed LED unit design.

Warnings

Tools required

Parts

• LED headlight assembly (left or right) × 1 — Use OEM specification
• Headlight assembly seal/gasket × 1 — Use OEM specification
• Push-pin retainers × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and wait 2 minutes for all systems to shut down
3. Open front trunk (frunk) to access 12V battery
4. Disconnect negative terminal on 12V battery and wait 5 minutes before proceeding
5. Photograph bumper fascia alignment points for reference during reassembly
6. Protect fender surfaces with masking tape or fender covers to prevent scratching

Procedure

1. 1

   Remove front wheel well liner (partial)
   Turn the steering wheel to full lock away from the side being serviced. Remove the three T30 Torx screws securing the forward section of the front wheel well liner. Pull the liner back to access the side bumper mounting points.
2. 2

   Remove upper grille panel
   Open the frunk fully. Locate and remove the four push-pin retainers securing the upper grille panel. Use a trim removal tool to carefully pry out the center pins, then remove the entire retainer. Lift the grille panel forward and up to disengage the lower clips, then set aside.
3. 3

   Disconnect frunk sensor harness
   Locate the frunk position sensor connector on the driver side near the latch mechanism. Press the release tab and disconnect the electrical connector. Route the harness free to allow bumper fascia removal.
4. 4

   Remove bumper fascia mounting bolts
   Remove the two 10mm bolts at the top of the bumper fascia accessible through the frunk opening. Remove one 10mm bolt on each side of the fascia behind the wheel well liner (accessed from step 1). Remove two T30 Torx screws underneath the bumper fascia at the lower edge, centered approximately 18 inches apart.
5. 5

   Release bumper fascia clips
   Starting at one corner, use a trim removal tool to carefully release the upper clips holding the bumper fascia to the front body panel. There are six clips total along the upper edge. Work slowly and evenly to avoid breaking clips. Support the bumper fascia as you release the final clips.
6. 6

   Remove bumper fascia
   With all fasteners and clips released, carefully pull the bumper fascia straight forward while supporting both sides. Watch for any remaining connected wiring. If equipped with front parking sensors, disconnect the sensor harness connectors before fully removing the fascia. Set the bumper fascia on a protected surface to prevent scratching.
7. 7

   Disconnect headlight electrical connectors
   Locate the headlight assembly main connector and DRL/turn signal connector on the back of the headlight unit. Press the release tabs and disconnect both connectors. If equipped with adaptive headlights, disconnect the third connector for the leveling motor.
8. 8

   Remove headlight assembly mounting fasteners
   Remove the three 10mm bolts securing the headlight assembly to the vehicle frame. One bolt is located at the top outer corner, one at the top inner corner near the frunk opening, and one at the lower inner position. Keep these bolts organized as they may have different lengths.
9. 9

   Remove headlight assembly
   Carefully pull the headlight assembly straight forward to disengage the alignment pins from the body. The assembly may be sealed with weatherstripping or adhesive - use steady, even pressure. Lift the assembly away from the vehicle and set on a clean, protected surface.
10. 10

    Inspect and clean mounting area
    Inspect the headlight mounting points and body alignment pins for damage or corrosion. Clean the mounting surface with a lint-free cloth. Check the condition of the rubber seal or weatherstripping and replace if deteriorated.
11. 11

    Install new headlight assembly
    Apply new seal or gasket to the replacement headlight assembly if required. Align the new headlight assembly with the body mounting pins and guide it into position. Ensure the assembly seats flush against the body panel before installing fasteners.
12. 12

    Secure headlight assembly and reconnect electrical
    Install and hand-tighten the three 10mm mounting bolts, then torque in a diagonal pattern to ensure even seating. Reconnect all electrical connectors to the headlight assembly, ensuring you hear an audible click on each connector. Verify connectors are fully seated.
13. 13

    Reinstall bumper fascia
    If equipped with parking sensors, reconnect the sensor harness connectors. Position the bumper fascia and align it with the body using the reference photos from preparation. Press firmly at each clip location to engage the upper retention clips. Install all mounting bolts and Torx screws, working from top to bottom.
14. 14

    Reconnect frunk sensor and reinstall grille
    Reconnect the frunk position sensor harness. Install the upper grille panel by engaging the lower clips first, then pressing down until the upper mounting points align. Install the four push-pin retainers. Reinstall the wheel well liner section with the three T30 Torx screws.
15. 15

    Reconnect battery and initialize system
    Reconnect the negative terminal on the 12V battery. Close the frunk and turn on the vehicle. The headlight system may require initialization - turn the headlights on and off three times, then cycle through all lighting modes to ensure proper operation.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify bumper fascia alignment matches pre-removal photographs
3. Check that all panel gaps are even and consistent with the opposite side
4. Confirm all push-pins and fasteners are properly installed

Verification

• Turn on headlights and verify low beam, high beam, and DRL functions operate correctly
• Activate turn signals and verify proper operation on the replaced side
• Check for proper headlight beam pattern and aim - adjust if necessary
• Verify no warning lights or errors appear on the instrument cluster
• Inspect all panels for proper alignment and secure mounting
• Test frunk operation to ensure sensor is functioning correctly
• Walk around vehicle to confirm no gaps or misalignment in bumper fascia

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