LED Headlight Module

This procedure covers removal and replacement of the LED headlight module assembly on a 2007-2013 Mercedes-Benz S65 AMG, including electrical disconnection, module extraction, and alignment verification.

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM specification - side specific
• Headlight module seal/gasket × 1 — Usually included with module

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key
3. Allow headlight system to cool for at least 20 minutes if recently operated
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal and wait 5 minutes for system discharge

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the negative cable from the battery post and secure it away from the terminal to prevent accidental reconnection during the procedure.
   Torque spec

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

   Remove front wheel well liner access panel
   Turn the steering wheel full lock away from the working side to access the wheel well. Remove the T20 Torx screws securing the front portion of the wheel well liner. Pull back the liner to expose the rear of the headlight assembly. This provides access to the electrical connectors and mounting hardware.
3. 3

   Remove headlight assembly cover
   Locate the plastic cover on the back of the headlight assembly accessible from the engine bay. Release the retaining clips and remove the cover to expose the electrical connectors and module mounting points. On some models, this cover is secured with T25 Torx screws.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
4. 4

   Disconnect electrical connectors
   Identify all electrical connectors to the LED module (typically 3-4 connectors including power supply, active cornering, and leveling system). Press the locking tabs and carefully disconnect each connector. Note the position and orientation of each connector for reassembly. Inspect connectors for corrosion or damage.
5. 5

   Disconnect ground strap
   Locate the ground strap connection on the headlight module or mounting bracket. Using an 8mm socket, remove the ground strap bolt. Ensure the mating surface is clean and free of corrosion for proper electrical contact during reassembly.
   ℹ️Clean contact surfaces with electrical contact cleaner and wire brush if corrosion is present.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)
6. 6

   Remove LED module mounting bolts
   Locate the module mounting bolts securing the LED headlight module to the housing (typically 3-4 bolts). Using the appropriate socket, remove all mounting bolts. Support the module with one hand while removing the final bolt to prevent it from dropping.
   Torque spec

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

   Extract LED module from housing
   Carefully pull the LED module straight back out of the headlight housing. The module may require gentle rocking to release from the alignment pins and seal. Do not force or pry against the module. If resistance is felt, verify all mounting bolts and connectors have been removed.
   ⚠Do not touch LED elements or internal optical surfaces. Oils from skin can cause hot spots and premature LED failure.
8. 8

   Inspect and clean mounting surfaces
   Inspect the headlight housing for cracks, moisture intrusion, or damage. Clean the mounting surface and alignment pin locations with a lint-free cloth. Verify the seal groove is clean and free of old gasket material or debris. Check that all alignment pins are intact and undamaged.
9. 9

   Install new LED module seal
   Install the new seal or gasket onto the replacement LED module according to the orientation marks. Ensure the seal is fully seated in its groove around the module perimeter. The seal prevents moisture intrusion into the headlight assembly.
10. 10

    Install replacement LED module
    Carefully align the new LED module with the alignment pins in the headlight housing. Push the module straight into the housing until it seats fully against the mounting surface. Verify the seal is not pinched or displaced during installation.
11. 11

    Install and torque module mounting bolts
    Install all module mounting bolts finger-tight first to ensure proper alignment. Then torque the mounting bolts in a cross-pattern sequence to the specified torque value to ensure even pressure distribution and proper sealing.
    Torque spec

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

    Reconnect ground strap
    Reconnect the ground strap to the headlight module or mounting bracket. Ensure the contact surface is clean and metal-to-metal contact is achieved. Torque the ground strap bolt to specification.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
13. 13

    Reconnect electrical connectors
    Reconnect all electrical connectors to the LED module in their original positions. Ensure each connector locks with an audible click. Apply a small amount of dielectric grease to connector seals if operating in harsh environments. Verify no wires are pinched or stressed.
14. 14

    Reinstall headlight cover and wheel well liner
    Reinstall the headlight assembly rear cover and secure any retaining clips or screws. Reposition the wheel well liner and install all T20 Torx screws. Ensure all fasteners are tight and no gaps exist that could allow water or debris entry.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
15. 15

    Reconnect battery and initialize system
    Reconnect the negative battery terminal and torque the terminal bolt to specification. Do not overtighten as this can damage the battery post. Turn the ignition to position II (without starting) and verify the headlight system initializes without fault codes on the instrument cluster.
    ℹ️The active headlight system may require several seconds to complete self-leveling initialization after battery reconnection.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Torque all fasteners to specification in the sequence provided
2. Ensure all electrical connectors are fully seated and locked
3. Verify headlight cover and wheel well liner are properly secured to prevent water intrusion
4. Check that no tools or parts have been left in the engine bay or wheel well

Verification

• With engine running, verify low beam, high beam, and cornering lights function properly on the replaced side
• Activate the active headlight leveling system by raising and lowering the vehicle suspension (if equipped with AIRMATIC) and verify smooth operation
• Check for any warning lights or messages on the instrument cluster related to the lighting system
• Verify headlight aim is correct - professional headlight alignment may be required after module replacement
• If fault codes persist or active functions do not operate, SCN coding at a Mercedes-Benz dealer with STAR Diagnosis system is required

Related trouble codes on this vehicle

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