Headlight Assembly

Procedure for removing and replacing the headlight assembly on a 2009 Aston Martin DB9 with 6.0L V12 engine, including access panel removal, electrical disconnection, and mounting hardware removal.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — 4G43-13W029-AA (left) or 4G43-13W030-AA (right)
• Push pin fasteners (if damaged during removal) — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition off and remove key
3. Open hood and prop securely
4. Disconnect negative battery terminal and wait 5 minutes to allow capacitors in HID system to discharge
5. Ensure headlights have cooled if recently operated

Procedure

1. 1

   Remove front wheel arch liner access panel
   From the engine bay side, locate the plastic access panel above the headlight assembly. Remove the Torx fasteners securing this panel. The panel provides access to the upper mounting points of the headlight assembly. Set the panel and fasteners aside in a clean area. Note: Remove headlight upper access panel from engine bay Note: Remove upper headlight access panel (engine bay side)
2. 2

   Disconnect headlight electrical connectors
   Locate the main headlight harness connector at the rear of the assembly. Press the release tab and pull the connector straight back to disconnect. Disconnect the secondary connector for the turn signal/parking light if equipped as a separate connector. Note the routing of the wiring harness for reassembly.
3. 3

   Remove upper headlight mounting bolts
   Locate the two upper mounting bolts securing the headlight assembly to the body. These upper mounting fasteners are accessible from above after the access panel is removed; verify head type and size against the service manual before selecting a tool. Remove both upper mounting bolts completely and set them aside. Note: These bolts are accessible from above after the access panel is removed; verify the exact bolt head size against the Aston Martin workshop manual before selecting a socket.
4. 4

   Access lower headlight mounting hardware
   The lower mounting point is accessed from the wheel well area. You may need to turn the steering wheel fully to one side for better access. Identify the lower mounting fastener securing the bottom of the headlight assembly to the body structure.
5. 5

   Remove lower headlight mounting bolt
   Remove the lower mounting bolt from the bottom of the headlight assembly, verifying head type and size against the service manual. Support the headlight assembly with one hand while removing this final fastener to prevent it from dropping. Note: Remove the lower mounting bolt from the bottom of the headlight assembly, verifying the correct bolt head size against the Aston Martin workshop manual.
6. 6

   Remove headlight assembly from vehicle
   With all mounting hardware removed and electrical connections disconnected, carefully pull the headlight assembly forward and out of the mounting position. Angle the assembly as needed to clear the body panel openings. The assembly may have locating pins that fit into grommets in the body, so a gentle rocking motion may be needed. Place the removed assembly on a clean, padded surface lens-side up.
7. 7

   Inspect mounting points and clean surfaces
   Inspect the body mounting points for damage, corrosion, or broken mounting grommets. Clean any dirt or debris from the mounting surfaces and electrical connector areas. Inspect the wiring harness for any signs of damage, chafing, or corrosion at the connector pins.
8. 8

   Prepare new headlight assembly
   Remove the new headlight assembly from its packaging carefully. Verify that all mounting brackets and adjustment hardware are present. Do not remove any protective films from the lens until installation is complete. Handle the assembly by the housing only, avoiding contact with the lens or any optical surfaces.
9. 9

   Install new headlight assembly
   Guide the new headlight assembly into position, aligning the locating pins with the mounting grommets in the body. Ensure the assembly is fully seated against the body panel before installing hardware. The electrical connectors should be accessible from the rear of the assembly.
10. 10

    Install lower mounting bolt
    Install the lower mounting bolt and thread it in by hand first to ensure proper thread engagement. Once hand-tight, torque the bolt to the manufacturer-specified value (verify in Aston Martin workshop manual) using a torque wrench whose range matches the specified value — confirm whether an M6, M8, or larger fastener is used before selecting the wrench. Do not overtighten as this can crack the headlight housing. Note: Once hand-tight, torque the bolt to the value specified in the Aston Martin workshop manual using a torque wrench of appropriate range.
    Torque spec

    Headlight Assembly Bolts10 Nm (7 lb-ft)
11. 11

    Install upper mounting bolts
    Install both upper mounting bolts, threading them in by hand initially. Once both are hand-tight and the headlight assembly is properly positioned, torque each bolt to specification in an alternating pattern to ensure even seating of the assembly.
    Torque spec

    Headlight Assembly Bolts10 Nm (7 lb-ft)
12. 12

    Reconnect electrical connectors
    Reconnect the main headlight harness connector to the rear of the assembly, pushing firmly until the locking tab clicks into place. Reconnect the turn signal/parking light connector if separate. Verify both connections are fully seated and locked. Route the wiring harness to avoid pinching or contact with sharp edges.
13. 13

    Reinstall access panel
    Reinstall the plastic access panel over the headlight mounting area, aligning all mounting points. Install the Torx fasteners and tighten securely but do not overtighten plastic fasteners.
14. 14

    Reconnect battery and test headlight operation
    Reconnect the negative battery terminal. Turn the ignition to the ON position and test all headlight functions: low beam, high beam, turn signals, and parking lights. If equipped with HID (xenon) headlights, they may take 5-10 seconds to reach full brightness on initial startup; verify lamp type for this vehicle. Verify there are no warning lights on the instrument cluster. Note: If equipped with HID headlights, they may take 5-10 seconds to reach full brightness on initial startup; verify bulb type for this vehicle.
15. 15

    Perform headlight aim adjustment if necessary
    If headlight aim is incorrect after installation, locate the horizontal and vertical adjustment screws on the rear of the headlight assembly. Use a Torx driver to turn the adjustment screws as needed to achieve proper beam pattern. The adjustment screws typically have a spring-loaded mechanism and should be turned carefully. Final adjustment should be performed at a proper headlight aiming facility or using an aiming device.
    Torque spec

    Adjuster Screws3 Nm (2 lb-ft)

Reassembly

1. Reassembly is covered in the installation steps above
2. Remove any protective film from the headlight lens only after installation is complete and testing is successful
3. If headlight aim is significantly off, professional alignment is recommended to ensure proper beam pattern and compliance with regulations

Verification

• Test all headlight functions with ignition on: low beam, high beam, turn signals, and parking lights
• Verify HID headlights reach full brightness within 10 seconds and maintain steady illumination without flickering
• Check that no warning lights appear on the instrument cluster related to lighting system
• Visually inspect headlight assembly for proper seating and alignment with body panels
• Verify no gaps exist between headlight assembly and body panel that could allow water intrusion
• Check headlight aim against a wall or garage door - beam pattern should be level and not pointed excessively high or to one side
• Ensure all electrical connectors are fully seated and locked with no exposed pins

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