Aston Martin DB9 Headlight Upgrade Installation Guide, A basic pictorial guide to installing DB9S Bi-LED upgraded headlights in an Aston Martin DB9 or DBS. These instructions show just the upgrade process, not removing the headlights from the car.
Tools needed
Tools needed are a hot air gun (or large oven), large broad flat screwdriver, sharp knife, ideally spreader pliers, small flat bade screwdriver, 5.5mm socket and black Sikaflex 221 sealant.
Remove the rear of the housing
As can be seen the DB9/DBS headlight is not manufactured in one piece and both the lens cover and the rear can be removed, to upgrade the module only the rear part needs to be separated.
Gently heat the 4 clips so they can be levered off the retaining tab. Then run a sharp knife, Stanley knife, through the sealant to help break the seal.
Using the heat gun gently heat the join between the two parts, starting with the underside near the HID ballast. Don’t hold the heat gun in one place but move it back and forth. Then using the large screwdriver gently lever between the ballast and the edge of the rear section of the housing, once it starts to open up then insert the separating pliers and whilst still heating work your way around the joint but don’t pull it too far away as the adjuster are still connected.
Use the small flat screwdriver to gently lever the two adjuster cables away from the adjuster on the bracket. and then remove the rear part of the housing.
remove the excess old sealant from the rear part of the housing, it may come out easily or may need some heat and a small screwdriver to remove it.
Remove the original projectors
Inside the rear of the DB9/DBS headlight (HID bulb already removed) with the screws shown in red, but remove the connectors first., the connector to the HID dipped beam, the main beam and the auto levelling motor.
Remove the five screws marked, using a 5.5mm socket and then withdraw the bracket and projectors.
The two connectors to the headlight ballast can now be disconnected. The loose cable from the ballast to the bulb can be discarded.
Remove the projector bezels using the same 5.5mm socket.
With the bezels removed we can now access the 4 screws holding the projector to the main bracket, again 5.5mm, remove these.
To allow the full range of adjustability, the bracket needs some small modifications, cut the lines marked in red with a hacksaw, ultrasonic knife, dremel or small angle grinder. This will allow the projectors to move through the entire arc of adjustment.
Remove the projector bracket from the projectors by sliding the levelling connector out the bottom of the module.
Install the new module by reversing the previous process, slide in the levelling ball (quite tight) and then swivel the bracket over and tighten the 4 screws up.
reinstall the headlight module and bracket in the headlight housing, tighten the 5 screws as before.
reconnect the wiring, main beam, dipped beam and auto levelling.
the next stage can get messy so have some latex gloves, install the Sikaflex 221 sealant into the groove of the rear part of the headlight housing then reinstall the cable adjusters
refit the cable headlight adjusters and then close the rear of the headlight up, ensuring that its is a snug fit all round and the clips are engaged, if any clips are broken use masking tape to hold in place and leave for 24 hours for the sealant to set.