Replace the LED headlight module on the 2017 Maserati Levante, including removal of the front bumper cover and disconnection of electrical connectors.

Warnings

Tools required

Parts

• LED headlight module × 1 — Use OEM specification
• Headlight module seal/gasket × 1 — Included with module or separate OEM

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn steering wheel to full lock away from the side being serviced for better access
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery terminal and wait 5 minutes before proceeding
5. Remove front wheel on the side being serviced for improved access to bumper fasteners
6. Photograph headlight position and adjustment marks before removal for easier reinstallation

Procedure

1. 1

   Disconnect battery
   Disconnect the negative battery terminal using a 10mm socket. Secure the cable away from the terminal post. Wait a minimum of 5 minutes to allow capacitors in the LED module to discharge completely.
   Torque spec

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

   Remove front wheel well liner
   Remove the front wheel well liner fasteners using a T25 Torx bit and trim removal tools. Pull back the liner to expose the side bumper mounting points and headlight access area. The liner provides access to several critical bumper fasteners.
3. 3

   Remove front bumper cover fasteners
   Remove the upper grille cover screws using T30 Torx bit. Remove lower bumper mounting bolts from underneath using 10mm socket. Remove side bumper mounting bolts accessible through the wheel well using 10mm socket. Carefully release plastic clips along the top edge of the bumper using trim removal tools.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Detach and support bumper cover
   With all fasteners removed, gently pull the bumper cover forward at the corners. Disconnect any fog light connectors or sensor harnesses behind the bumper. Have an assistant support the bumper or place it on a padded surface to prevent damage. Complete removal is not necessary; bumper can be pulled forward and supported.
5. 5

   Access headlight module mounting
   With bumper pulled forward, locate the LED headlight module mounting bolts at the top and side of the assembly. Remove the access covers if present using an 8mm socket. Note the position of any adjustment screws before disturbing them.
6. 6

   Disconnect headlight electrical connectors
   Locate the main LED module connector at the rear of the headlight assembly. Depress the locking tab and carefully disconnect the connector. Also disconnect any separate connectors for the leveling motor, turn signal, or DRL if equipped. Clean connector terminals with electrical contact cleaner if corrosion is present.
7. 7

   Remove headlight module mounting bolts
   Remove the three module mounting bolts securing the headlight assembly to the vehicle frame using a 10mm socket. Support the headlight module with one hand while removing the final bolt to prevent it from falling. Carefully pull the assembly forward and out of the mounting position.
   ⚠LED module is heavy and awkward to handle. Use both hands and avoid dropping or impacting the assembly.
   Torque spec

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

   Remove old seal and prepare mounting surface
   Remove the old headlight seal or gasket from the mounting surface on both the vehicle and the old module if transferring components. Clean the mounting surface thoroughly with a clean cloth to remove dirt, debris, or old adhesive. Ensure the mounting bracket and adjustment points are clean and free of corrosion.
9. 9

   Install new seal on replacement module
   Position the new seal or gasket on the replacement LED headlight module, ensuring it is properly seated in the channel around the perimeter. Verify the seal is continuous with no gaps or overlaps. Apply dielectric grease to all electrical connector pins on the new module.
10. 10

    Position and align new headlight module
    Carefully position the new LED module into the mounting location, aligning the mounting holes with the brackets. Ensure wiring harnesses are routed properly and not pinched. Hand-thread all three mounting bolts before tightening any of them to ensure proper alignment.
11. 11

    Torque headlight mounting bolts
    Torque the module mounting bolts to specification in a cross-pattern to ensure even pressure on the seal. Start with the top bolt, then alternate between the lower bolts. Verify the module is flush against the mounting surface with no gaps.
    Torque spec

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

    Reconnect electrical connectors
    Reconnect the main LED module connector, ensuring it clicks into place and the locking tab engages fully. Reconnect any secondary connectors for leveling motor, turn signal, or DRL. Gently tug each connector to verify secure connection.
13. 13

    Reinstall front bumper cover
    Position the front bumper cover back onto the vehicle, reconnecting any fog light or sensor connectors. Align the bumper carefully to ensure even gaps around the hood and fenders. Install and torque all mounting bolts and screws. Secure all plastic clips along the top edge. Reinstall wheel well liner fasteners.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
14. 14

    Reconnect battery and initialize system
    Reconnect the negative battery terminal and torque to specification. Do not overtighten. Turn the ignition to the ON position without starting the engine. Verify the LED headlight module powers on and performs a self-test (module may move or flash). Check for any error messages on the dashboard.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Reinstall front wheel and torque lug nuts to manufacturer specification
2. Verify all bumper fasteners are tight and properly seated
3. Check that all electrical connectors are fully engaged with locking tabs secured
4. Ensure wheel well liner is properly reinstalled to prevent water intrusion

Verification

• Turn on headlights and verify proper LED illumination with no dark spots or flickering
• Test low beam, high beam, and DRL functions independently
• Verify turn signal operation on the replaced side
• Check automatic leveling function by starting vehicle and observing headlight self-adjustment
• Inspect headlight aim and adjust if necessary using adjustment screws at the rear of the module
• Verify no warning lights or error messages on the dashboard
• Test headlight washer function if equipped
• Check for proper sealing by inspecting for gaps between module and body

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