Replacement of a front headlight assembly on a 2024 Tesla Model 3 Performance. Access requires removing the front fascia or at minimum loosening the wheel liner and front bumper edge to reach the headlight mounting bolts and connector.

Warnings

Tools required

Parts

• Front headlight assembly (Model 3 Performance, matching LH or RH side) × 1 — Tesla OEM matrix LED headlight assembly — verify side and trim before ordering
• Replacement push-pin retainers / trim clips × 6 — Manufacturer-specified fascia/wheel liner clips (often damaged on removal)

Preparation

1. Park on level ground, place in P, engage the parking brake.
2. Exit ALL doors with the key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 12V low-voltage battery. On 2024 Model 3, the LV battery is typically accessible behind the right rear seat back panel or under the rear floor area depending on build — refer to architecture notes and confirm before disconnecting. Torque the terminal back later to spec.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. Turn the steering wheel to provide access to the wheel liner on the side being serviced.
7. Place fender covers over the front fender and hood edge to protect paint and the aluminum hood.
8. Open the frunk and remove the frunk liner/tub to expose the upper headlight mounting area and connector routing.
9. Verify the replacement headlight assembly is the correct side and matches the original (matrix/adaptive variant) before disassembly.

Procedure

1. 1

   Remove front wheel liner fasteners (affected side)
   Turn the steering to expose the front wheel liner. Remove the push-pin retainers and Torx screws securing the forward portion of the wheel liner to the fascia. Pull the liner back enough to access the fascia-to-fender fastener behind it.
2. 2

   Release the front fascia edge
   Remove the fascia-to-fender fastener (typically one screw per side behind the wheel liner). Carefully release the fascia tab from the fender clip by pulling outward at the wheel arch. Repeat on the opposite side if full fascia removal is required for headlight clearance.
   ⚠Do not pry between fascia and fender — the painted aluminum fender will dent. Pull straight outward by hand.
3. 3

   Remove upper fascia fasteners
   From inside the frunk opening, remove the fasteners along the upper edge of the front fascia and the radiator support cover. Disengage any clips along the top that retain the fascia to the upper crossmember.
4. 4

   Lower fascia and disconnect harnesses (if removing fascia)
   With assistance, support the fascia and gently pull it forward off the upper retaining clips. Disconnect any electrical connectors (parking sensors, cameras, ambient temp sensor, fog/DRL if present) before fully removing. Set the fascia on a padded surface to avoid scratches.
   ⚠Front fascia houses radar/camera and ultrasonic sensors. Handle carefully and do not let the fascia hang by its harnesses.
5. 5

   Disconnect headlight electrical connector
   Locate the main connector at the rear of the headlight assembly. Release the connector lock (typically a slide or lever lock) and disconnect. Inspect the connector and pins for corrosion or heat damage and report findings.
6. 6

   Remove headlight assembly mounting bolts
   Remove the bolts securing the headlight assembly to the upper radiator support and fender bracket — typically three mounting points (upper, inboard, and outboard). Note the location of each bolt for reinstallation.
   Torque spec

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

   Remove the headlight assembly
   Pull the headlight assembly forward out of its locating tabs. The lower edge typically has a locating peg that engages a grommet in the body — work the assembly forward, not upward, to release it without damage.
   ⚠Do not let the lens contact the fender or fascia — modern matrix headlight lenses scratch easily.
8. 8

   Transfer brackets if required
   Compare the new assembly to the original. If any mounting brackets, adjuster screws, or retaining tabs are separate components, transfer them to the new assembly using the manufacturer-specified hardware.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)

   Adjuster Screws3 Nm (2 lb-ft)
9. 9

   Install new headlight assembly
   Engage the lower locating peg into the body grommet first, then pivot the assembly into position. Hand-start all mounting bolts before final tightening to ensure proper alignment with the fender and hood gap.
   Torque spec

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

    Torque headlight mounting bolts
    Torque all headlight assembly mounting bolts to specification in a cross pattern. Verify the headlight sits flush with the fender and fascia gap is even before final torque.
    Torque spec

    Headlight Assembly Bolts10 Nm (7 lb-ft)
11. 11

    Reconnect headlight harness
    Plug the headlight connector in fully until the lock engages. Ensure the connector is seated squarely — partial engagement causes intermittent matrix-LED faults.
    Torque spec

    Connector Screws4 Nm (3 lb-ft)

Reassembly

1. Reinstall the front fascia: align upper clips first, then press fender tabs into the fender clips by hand.
2. Reconnect all fascia harnesses (sensors, cameras, ambient temp) before fully seating the fascia.
3. Reinstall upper fascia fasteners and radiator support cover.
4. Reinstall the fascia-to-fender screw behind the wheel liner on each side serviced.
5. Reinstall wheel liner fasteners and any push-pins. Replace any broken clips with new ones.
6. Reinstall the frunk liner/tub.
7. Reconnect the 12V low-voltage battery and torque the terminal bolt to specification.
8. Close frunk and verify even panel gaps to fender, hood, and fascia.

Verification

• Power the vehicle on (foot on brake) and verify low beam, high beam, DRL, turn signal, and side marker functions on the replaced side.
• If the vehicle is equipped with adaptive/matrix headlights, observe behavior at night or in a dark environment — verify auto high beam and adaptive segment function. If non-functional, the assembly likely requires Tesla Toolbox coding/calibration at a Service Center.
• Check the touchscreen for any headlight-related alerts (e.g., 'Headlight system needs service'). Clear and re-check after a drive cycle.
• Perform headlight aim verification against a wall target at the manufacturer-specified distance, or have aim verified at a service facility.
• Inspect panel gaps between headlight, fender, hood, and fascia — they should be even and flush. Adjust using the headlight adjuster screws if minor correction is needed.
• While the front end is apart, this is a good time to note other interval-based service: cabin air filter (every 2 years), brake fluid (every 2 years), and tire rotation (every 6,250 mi) — none are required by this job but are commonly overdue on Model 3.

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