Replacement of both left and right headlight assemblies on a 2024 Tesla Model S Long Range AWD. Requires partial front fascia removal for access to mounting hardware and connectors, followed by adaptive headlight calibration via the touchscreen.

Warnings

Tools required

Parts

• Left (driver) headlight assembly — Model S Refresh (2021+) × 1 — OEM Tesla LH headlight assembly for 2024 Model S
• Right (passenger) headlight assembly — Model S Refresh (2021+) × 1 — OEM Tesla RH headlight assembly for 2024 Model S
• Replacement plastic fascia clips/retainers (commonly damaged on removal) × 1 — Generic Tesla front fascia retainer clip set

Preparation

1. Park on level ground, place in P, and 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 located in the front trunk (frunk), under the nose cowl panel. Torque battery terminal bolts only when reconnecting later.
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. Open the frunk and place a soft moving blanket over the front fascia and fenders to protect aluminum panels from tool contact.
7. Verify replacement headlights match the VIN build (matrix LED vs. standard LED variants exist on refresh Model S).
8. Allow the existing headlights to cool fully before handling — LED housings retain heat.

Procedure

1. 1

   Remove frunk liner and access upper fascia hardware
   Open the frunk. Remove the plastic frunk tub/liner by releasing its perimeter push-pin retainers and lifting it out. This exposes the upper edge of the front fascia and the upper mounting points of both headlight assemblies.
2. 2

   Release upper fascia retainers
   Working along the top edge of the front fascia (between the hood/frunk opening and the bumper cover), release the row of plastic push-pin clips and any Torx fasteners securing the fascia top to the radiator support. Place fasteners in a labeled tray. Expect to break 1–2 clips on a vehicle that has been opened before — have replacements ready.
   ⚠Do not pry against painted aluminum body panels. Use plastic trim tools only.
3. 3

   Release wheel-well liner front edge
   Turn the steering to full lock on each side in turn (steering will move freely with 12V disconnected only if the column is unlocked before disconnecting; otherwise work straight-ahead). Pull back the front edge of each wheel arch liner by removing the two to three Torx fasteners and any push-pins where the liner meets the fascia. This exposes the side mounting tabs of the fascia and headlight.
4. 4

   Partially detach front fascia
   With upper and side retainers released, gently pull the front fascia forward a few inches at the upper corners, just enough to expose the rear of each headlight assembly and its harness connector. Full fascia removal is generally not required for headlight replacement on the refresh Model S, but support the fascia with a strap or assistant if pulling it further.
   ⚠Parking sensors, ambient temp sensor, and (if equipped) front camera washers may be tethered to the fascia. Do not yank — disconnect any harness that becomes taut.
5. 5

   Disconnect headlight harness
   Locate the main headlight connector at the rear of each assembly. Depress the locking tab fully and pull straight back — do not rock side-to-side. If a secondary connector is present for adaptive/matrix function, disconnect it as well.
6. 6

   Remove headlight mounting fasteners
   Each headlight assembly is retained by mounting bolts at the top, side, and lower tab into the radiator support / front structure. Remove all assembly mounting bolts and retain them — bolt lengths may differ by location, so keep them organized.
   Torque spec

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

   Extract the headlight assembly
   Pull the headlight straight forward out of its locating dowels in the radiator support. If it resists, verify all fasteners are removed and that no harness is still clipped to the housing. Set the old assembly lens-up on a padded surface.
   ⚠Do not let the assembly drop against the painted fender — aluminum dents permanently from a single impact.
8. 8

   Repeat for opposite side
   Perform steps 5–7 on the opposite headlight. Inspect both housings' locating dowels in the radiator support for damage; clean any debris from the mounting pockets before installing new units.
9. 9

   Install new headlight assemblies
   Align each new headlight onto its locating dowels and seat it fully. Hand-start all mounting bolts before torquing any one of them, to avoid binding. Then torque the headlight mounting bolts to the OEM specification.
   ℹ️If the verified torque list contains two 'Mounting Bolts' values, refer to the Tesla Service Manual for the specific value applicable to front lighting fasteners — do not guess.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect headlight harness
    Push each connector straight in until the locking tab clicks. Verify the lock is fully engaged by tugging gently on the connector body (not the wires).

Reassembly

1. Reseat the front fascia onto its upper and side retainers, pressing each clip until it clicks. Replace any broken clips.
2. Reinstall fascia upper Torx fasteners and push-pins.
3. Reinstall both wheel arch liner front edges with their Torx fasteners and push-pins.
4. Reinstall the frunk liner and its retainers.
5. Reconnect the 12V battery in the frunk, negative terminal last. Torque the battery terminal bolts — do not overtighten.
6. Close frunk and confirm latch engagement.

Verification

• Power up the vehicle by sitting in the driver's seat with the key fob present. Allow the system to fully boot.
• Cycle low beams, high beams, turn signals, DRLs, and side marker function on both sides. Confirm no bulb-out or lighting fault warnings appear on the touchscreen.
• On the touchscreen, navigate to Service / Software and check for any 'headlight', 'matrix', or 'ADB' (adaptive driving beam) related faults. Clear and re-test if available.
• If equipped with adaptive matrix headlights, perform aim and matrix calibration per Tesla Service Manual procedure — this typically requires a known-distance target wall and should be done before returning the vehicle to the customer.
• Verify Autopilot front camera still functions correctly (Autopilot uses a windshield-mounted camera, not the headlights, but a misaligned fascia can obstruct front parking sensors). Drive at low speed and confirm no parking sensor or camera faults.
• Visually confirm fascia gaps to fender and hood are even on both sides — uneven gaps indicate the fascia is not fully seated on its retainers.
• Reminder: while in the front of the vehicle, this is a good opportunity to check 12V battery age (3–5 year typical AGM service life) and cabin air filter interval (every 2 years, or 3 years for HEPA-equipped vehicles).

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