Headlight Assembly - Pair

This procedure covers the removal and replacement of both left and right headlight assemblies on a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine, including disconnection of electrical connectors and module transfers.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification
• Right headlight assembly × 1 — Use OEM specification
• Headlight mounting seals/gaskets × 2 — Included with OEM headlights or order separately

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and remove key from ignition
3. Allow engine to cool completely if recently driven
4. Open hood and secure with prop rod
5. Photograph headlight connector locations and orientations for reference
6. Prepare clean workspace for headlight assemblies

Procedure

1. 1

   Disconnect battery negative terminal
   Locate the battery in the engine bay. Using a 10mm socket, loosen and remove the negative terminal bolt. Disconnect the negative cable and secure it away from the battery post to prevent accidental reconnection. Wait at least 2 minutes for capacitive discharge from HID/LED systems.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove front bumper cover fasteners
   Remove the upper grille assembly by releasing the clips along the top edge. Remove T25 Torx screws securing the headlight access panels behind the grille. Remove T30 Torx screws along the top of the bumper cover near each headlight. You do not need to fully remove the bumper, but must release the forward sections near both headlights.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Access and remove driver side headlight mounting bolts
   Working from above, locate the three headlight mounting bolts on the driver side assembly (top and sides). Use a 10mm socket to remove all three mounting bolts. Keep bolts organized as they may vary in length. Carefully pull the top edge of the bumper cover forward slightly to create working clearance.
   ⚠Support the headlight assembly while removing the final bolt to prevent it from falling.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
4. 4

   Disconnect driver side electrical connectors
   Reach behind the driver side headlight assembly and locate all electrical connectors (typically 2-4 connectors for main power, cornering lamp, DRL, and adaptive headlight module if equipped). Depress the locking tabs and carefully disconnect each connector. If equipped with adaptive headlight module, remove the module mounting bolts and disconnect the module connector.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Remove driver side headlight assembly
   With all electrical connections disconnected and mounting bolts removed, carefully pull the driver side headlight assembly forward and out of the vehicle. Guide it through the bumper opening, being careful not to scratch the paint or damage the assembly. Place on a clean, padded surface.
6. 6

   Access and remove passenger side headlight mounting bolts
   Repeat the process on the passenger side. Locate and remove the three headlight mounting bolts using a 10mm socket. Pull the bumper cover edge forward slightly for clearance if needed.
   ⚠Support the headlight assembly while removing the final bolt to prevent it from falling.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Disconnect passenger side electrical connectors
   Reach behind the passenger side headlight assembly and disconnect all electrical connectors by depressing the locking tabs. If equipped with adaptive headlight module, remove module mounting bolts and disconnect the module.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Remove passenger side headlight assembly
   With all connections disconnected and bolts removed, carefully pull the passenger side headlight assembly forward and out of the vehicle. Guide it through the bumper opening and place on a clean, padded surface next to the driver side assembly.
9. 9

   Transfer modules and inspect mounting points
   If reusing adaptive headlight modules, cornering lamps, or other components, carefully transfer them from old assemblies to new assemblies following reverse removal procedure. Clean the headlight mounting surfaces on the vehicle body and inspect mounting brackets for damage. Check that all mounting holes are clean and free of corrosion.
10. 10

    Install passenger side headlight assembly
    Install new mounting seals/gaskets on the passenger side headlight if provided separately. Carefully guide the new passenger side headlight assembly into position through the bumper opening. Align all mounting points and hand-start all three mounting bolts before tightening. Using a torque wrench, tighten mounting bolts to specification in a cross-pattern.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Connect passenger side electrical connectors
    Reconnect all electrical connectors to the passenger side headlight assembly, ensuring each connector locks into place with an audible click. If equipped with adaptive headlight module, reinstall module to the headlight assembly, torque module mounting bolts to specification, and connect module connector.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Install driver side headlight assembly
    Install new mounting seals/gaskets on the driver side headlight if provided separately. Carefully guide the new driver side headlight assembly into position. Align all mounting points and hand-start all three mounting bolts. Using a torque wrench, tighten mounting bolts to specification in a cross-pattern.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
13. 13

    Connect driver side electrical connectors
    Reconnect all electrical connectors to the driver side headlight assembly, ensuring proper engagement and locking. If equipped with adaptive headlight module, reinstall module to headlight assembly, torque module mounting bolts to specification, and connect module connector.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
14. 14

    Reinstall bumper cover components and reconnect battery
    Reinstall all bumper cover T30 Torx screws along the top edge near both headlights. Reinstall headlight access panels and secure with T25 Torx screws. Reinstall upper grille assembly. Reconnect the battery negative terminal and torque to specification using a torque wrench. Do not overtighten.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked before testing
2. Verify bumper cover alignment is correct and all fasteners are secure
3. Do not slam hood after installation; close gently to avoid headlight misalignment

Verification

• Turn ignition to ON position and verify both headlights illuminate (low beam, high beam, and DRL)
• Test turn signals and cornering lamps on both sides
• If equipped with adaptive headlights, start engine and verify modules perform initialization sweep
• Check headlight aim and adjust if necessary using aim adjustment screws on rear of assemblies
• Inspect around headlight perimeter for proper sealing and alignment with bumper cover
• Verify no warning lights on instrument cluster related to headlight system
• Test all lighting functions while someone walks around vehicle to confirm proper operation

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