This procedure covers the replacement of both headlight bulb assemblies on the 2025 Rivian EDV 500 commercial delivery van, requiring removal of front fascia components and headlight housing access panels.

Warnings

Tools required

Parts

• Driver side LED headlight bulb assembly × 1 — Use OEM specification - Rivian Part
• Passenger side LED headlight bulb assembly × 1 — Use OEM specification - Rivian Part
• Headlight housing seal gaskets × 2 — Use OEM specification if damaged
• Plastic trim clips × 4 — Replace any broken clips

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off the vehicle completely using the center screen shutdown procedure
3. Wait 10 minutes for headlight control modules to fully discharge
4. Open the front hood and secure with prop rod
5. Ensure workspace has adequate lighting for viewing internal components
6. Inspect new LED bulb assemblies to verify correct part numbers match vehicle specification

Procedure

1. 1

   Remove front wheel well liner access panels
   Turn the front wheels fully to the side opposite of the headlight being serviced. Remove the three T25 Torx screws securing the forward section of the wheel well liner. Carefully pull back the liner to expose the rear access area of the headlight housing. This provides access to the bulb connector from behind.
2. 2

   Disconnect headlight electrical connector
   Locate the main headlight bulb connector behind the headlight housing, accessible through the wheel well. Press the locking tab and pull the connector straight back from the bulb assembly. Note the orientation of the connector for reinstallation. If connector is tight, gently rock it side to side while pulling.
3. 3

   Remove headlight housing access cover
   From the engine compartment, locate the circular or rectangular access cover on the rear of the headlight housing. Rotate the cover counterclockwise approximately 1/4 turn and pull straight out. This exposes the bulb retention mechanism inside the housing.
4. 4

   Release bulb retention clip
   Inside the headlight housing, locate the wire retention clip that secures the bulb assembly. Press down and unhook the spring clip, then swing it out of the way. The clip design may vary but typically pivots from one side. Take care not to touch the reflector surface inside the housing.
5. 5

   Remove old headlight bulb assembly
   With the retention clip released, carefully pull the bulb assembly straight out of the housing. The bulb may require a gentle rocking motion to free it from the socket. Avoid twisting or forcing the bulb. Inspect the rubber seal on the bulb base for damage.
6. 6

   Inspect headlight housing and clean if needed
   With the bulb removed, visually inspect the housing interior for moisture, debris, or damage. Use a microfiber cloth to gently clean the bulb socket area if needed. Check that the housing seal is intact and properly seated. Do not touch reflector surfaces with bare hands.
7. 7

   Install new headlight bulb assembly
   Remove the new LED bulb from its protective packaging, handling only by the base. Align the bulb tabs with the housing slots and insert straight into the socket until fully seated. The bulb will only fit in one orientation. Ensure the rubber seal on the bulb base makes proper contact with the housing.
8. 8

   Secure bulb with retention clip
   Swing the wire retention clip back over the bulb base and hook it into place. Apply firm pressure to ensure the clip is fully engaged and the bulb is held securely. Verify the bulb cannot be pulled out easily.
9. 9

   Reconnect electrical connector
   From the wheel well access area, align the electrical connector with the bulb terminals and push straight in until the locking tab clicks into place. Gently tug on the connector to verify it is secure. Ensure no wires are pinched or stressed.
10. 10

    Reinstall housing access cover
    Place the access cover back onto the rear of the headlight housing, aligning the tabs. Rotate clockwise approximately 1/4 turn until it locks into position. The cover should sit flush against the housing.
11. 11

    Restore wheel well liner
    Pull the wheel well liner back into its original position. Reinstall the three T25 Torx screws, tightening securely but not over-torquing the plastic fasteners. Verify the liner is properly seated and not interfering with any moving components.
12. 12

    Repeat procedure for opposite side
    Complete steps 1 through 11 for the opposite side headlight bulb assembly. Maintain the same care and attention to connector orientation and bulb handling. Both headlights should be replaced as a pair to ensure even light output and color matching.

Reassembly

1. Verify all access covers and wheel well liner panels are securely reinstalled
2. Ensure all electrical connectors are fully seated and locked
3. Return front wheels to straight-ahead position
4. Close and secure the front hood

Verification

• Power on the vehicle and activate the headlights to verify both new bulbs illuminate properly
• Check that both low beam and high beam functions work correctly on each side
• Verify DRL (Daytime Running Lights) function operates normally if equipped
• Inspect for any error messages on the instrument cluster related to lighting systems
• Visually confirm light output is even between both headlights with matched color temperature
• Test automatic headlight leveling system if equipped by bouncing suspension and observing beam adjustment
• Perform a short test drive to verify headlight aim and proper operation under driving conditions

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