This procedure covers the removal and replacement of the LED headlight module on a 2025 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification
• Headlight mounting gasket × 1 — Use OEM specification
• Push pin fasteners (replacement) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Power off vehicle completely using main power button
3. Disconnect 12V auxiliary battery negative terminal and secure away from terminal
4. Wait minimum 5 minutes for capacitors to discharge
5. Cover front bumper and fender with protective material to prevent scratches
6. Ensure replacement headlight module is at room temperature if stored in cold environment

Procedure

1. 1

   Access front bumper area
   Open the front cargo area or hood access panel. Locate and remove the four push pin fasteners securing the upper radiator cover panel using the panel removal tool. Carefully lift and remove the panel to expose the headlight mounting area.
2. 2

   Remove wheel well liner access panel
   Turn the steering wheel fully to the opposite side of the headlight being replaced for better access. Locate the wheel well liner access panel on the forward section. Remove three Torx T25 screws securing the access panel and fold back the liner to expose the rear of the headlight assembly.
3. 3

   Disconnect electrical connectors
   Locate the main headlight harness connector at the rear of the headlight assembly. Press the locking tab and carefully disconnect the main connector. Disconnect the secondary connector for the LED position light by pressing the red locking tab and pulling straight back. Note connector orientation for reassembly.
   ⚠Do not pull on wires. Always grip the connector body when disconnecting to prevent terminal damage.
4. 4

   Remove headlight mounting fasteners
   Remove the two Torx T30 screws at the top of the headlight assembly accessible from the engine bay area. Remove the single Torx T30 screw on the outer edge of the headlight near the fender. Remove the lower 10mm bolt accessible through the wheel well liner opening.
5. 5

   Release headlight assembly clips
   Locate the two spring clips on the inboard side of the headlight assembly. Using a panel tool, carefully press the clips toward the center of the vehicle while applying gentle outward pressure on the headlight assembly. The clips will release with a distinct click.
6. 6

   Remove headlight assembly
   With all fasteners and clips released, carefully pull the headlight assembly straight forward and outward from the vehicle. The assembly slides on alignment pins. If resistance is felt, verify all fasteners are removed. Guide the assembly away from the fender and bumper to avoid scratching painted surfaces.
   ⚠Headlight assembly weighs approximately 8 pounds. Support it with both hands during removal.
7. 7

   Inspect mounting surface and gasket
   Examine the headlight mounting surface on the vehicle for damage, cracks, or debris. Check the condition of the mounting gasket that seals the headlight to the body. Remove the old gasket if torn or compressed. Clean the mounting surface with a clean microfiber cloth to ensure proper seal.
8. 8

   Prepare new headlight assembly
   Remove the new LED headlight module from its packaging. Inspect for shipping damage. Install the new mounting gasket onto the rear of the headlight assembly if not pre-installed. Ensure the gasket is properly seated in the groove around the perimeter. Clean any fingerprints from the lens with a lint-free cloth.
9. 9

   Install new headlight assembly
   Position the new headlight assembly at the mounting location. Align the locating pins on the rear of the assembly with the corresponding holes in the body mounting surface. Carefully slide the assembly straight into position until it contacts the mounting surface. Ensure the gasket is not pinched or displaced.
10. 10

    Secure headlight mounting fasteners
    Install the two Torx T30 screws at the top of the headlight assembly and hand-tighten. Install the outer Torx T30 screw near the fender and hand-tighten. Install the lower 10mm bolt through the wheel well opening and hand-tighten. Once all fasteners are started, tighten them in a diagonal pattern to ensure even pressure distribution. Tighten securely but do not over-torque.
11. 11

    Engage headlight mounting clips
    Press firmly on the inboard edge of the headlight assembly until the two spring clips engage with an audible click. Verify the clips are fully seated by attempting to pull the assembly outward gently; it should not move.
12. 12

    Reconnect electrical connectors
    Connect the secondary LED position light connector first, pushing until the red locking tab clicks into place. Connect the main headlight harness connector, ensuring proper alignment of the keyway, and push firmly until the locking tab engages with a click. Gently tug on each connector to verify secure connection.
13. 13

    Reinstall wheel well liner and access panels
    Reposition the wheel well liner and secure with the three Torx T25 screws. Ensure the liner is properly seated and does not interfere with any wiring. Install new push pin fasteners if originals were damaged. Reinstall the upper radiator cover panel and secure with the four push pin fasteners.

Reassembly

1. Verify all fasteners are tightened and no tools or parts are left in the engine bay or wheel well
2. Ensure all electrical connectors are fully seated and locked
3. Reconnect 12V auxiliary battery negative terminal
4. Return steering wheel to center position

Verification

• Power on the vehicle and verify the headlight module initializes without error messages on the instrument cluster
• Test all headlight functions: low beam, high beam, daytime running lights, and turn signals
• Visually inspect headlight operation from outside the vehicle to confirm proper illumination pattern
• Check for proper sealing by inspecting the gasket perimeter for uniform compression
• Perform headlight aiming procedure using manufacturer-specified equipment or take vehicle to qualified technician for proper aim adjustment
• Test drive vehicle in dark conditions to verify proper headlight function and aim before returning to service

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