Headlight Assembly

This procedure covers the removal and installation of the headlight assembly on a 2007-2013 Mercedes-Benz S65 AMG, including disconnection of electrical connectors and proper alignment.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — A221-820-XX-61 or A221-820-XX-60 (specify side)
• Plastic trim clips (if broken) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn headlights and ignition off
3. Disconnect negative battery terminal and wait 5 minutes for capacitor discharge
4. Allow headlights to cool completely if vehicle was recently driven
5. Prepare clean workspace for removed headlight assembly

Procedure

1. 1

   Remove front bumper cover screws
   Open hood fully. Locate and remove the T25 Torx screws securing the upper portion of the front bumper cover to the headlight area. There are typically 2-3 screws along the top edge near each headlight. Remove the plastic clips securing the bumper cover to the fender liner in the wheel well area on the side being serviced.
2. 2

   Remove headlight access cover
   Locate the plastic access cover behind the headlight assembly in the engine bay. Remove the retaining screws using a T20 Torx bit. Carefully pull the cover away to expose the rear of the headlight assembly and electrical connections.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
3. 3

   Disconnect headlight electrical connectors
   Identify all electrical connectors at the rear of the headlight: main headlight connector, ballast connector (Bi-Xenon), and Active Curve motor connector if equipped. Press the release tabs and carefully disconnect each connector. Note the routing and position of wiring harnesses for reinstallation.
4. 4

   Remove headlight adjuster screws
   Locate the two headlight adjustment screws accessible from the top of the headlight assembly. These control vertical and horizontal aim. Using a T25 Torx bit, turn each adjuster counterclockwise to release tension, but do not fully remove unless replacing adjusters.
   ℹ️Mark or photograph adjuster positions before disturbing to simplify re-aiming procedure.
   Torque spec

   Adjuster Screws3 Nm (2 lb-ft)
5. 5

   Remove headlight mounting bolts
   Locate the three main mounting bolts securing the headlight assembly to the front body structure. Two bolts are typically accessible from the top, and one from the side or bottom. Use a 10mm socket to remove these bolts completely. Keep bolts organized for reinstallation.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
6. 6

   Remove headlight assembly
   Gently pull the headlight assembly forward and outward from the vehicle. The assembly may have locating pins at the rear that need to clear their receptacles. Tilt or angle the assembly as needed to clear the bumper cover and fender. Support the assembly weight to prevent dropping.
   ⚠Headlight assembly weighs approximately 10-12 lbs and is awkward to handle. Use both hands and ensure clear path before removing.
7. 7

   Inspect mounting points and clean surfaces
   With headlight removed, inspect the body mounting points for corrosion or damage. Clean all mounting surfaces with a clean cloth. Check the alignment pins and grommets for wear. Inspect the bumper cover tabs for cracks. If installing a used headlight, clean the lens and housing with appropriate cleaner.
8. 8

   Install new or replacement headlight assembly
   Position the headlight assembly near the mounting location. Align the rear locating pins with their receptacles in the body structure. Carefully guide the assembly into place, ensuring it seats fully against the mounting surface and aligns with the bumper cover opening. Do not force the assembly.
9. 9

   Install headlight mounting bolts
   Thread all three mounting bolts by hand first to ensure proper alignment. Once all bolts are started, tighten them in a cross pattern using a torque wrench to the specified value. Verify the headlight is flush with surrounding body panels before final torquing.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect all electrical connectors to the rear of the headlight assembly in the reverse order of removal. Ensure each connector clicks fully into place and the locking tabs engage. Route wiring harnesses in their original positions to avoid pinching or interference.
11. 11

    Reinstall access cover and bumper components
    Position the rear access cover and secure with the retaining screws, torquing to specification. Reinstall any bumper cover screws and clips that were removed. Ensure all trim pieces are properly seated and aligned.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
12. 12

    Reconnect battery and perform initial test
    Reconnect the negative battery terminal and torque to specification. Turn the ignition to position II (without starting) and activate the headlights to verify operation. Test low beam, high beam, and turn signal functions. If equipped with Active Curve, observe self-leveling and steering-responsive movement.

Reassembly

1. Torque all fasteners to specified values using a calibrated torque wrench
2. Verify all electrical connectors are fully seated and locked
3. Ensure headlight assembly is flush with body panels and bumper cover alignment is correct
4. Check that no wiring is pinched or in contact with sharp edges

Verification

• Test all headlight functions: low beam, high beam, turn signals, and parking lights
• Verify Active Curve self-leveling completes without error (if equipped)
• Check for proper headlight aim using a wall or headlight aiming equipment, adjust as needed
• Inspect for any warning lights on the instrument cluster related to lighting systems
• Verify no light leakage around headlight assembly seals
• Test operation several times to ensure consistent function

Related trouble codes on this vehicle

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