Replacement of a front headlight assembly on a 2024 Tesla Model S Plaid. The job requires partial removal of the front fascia or wheel arch liner to access the headlight mounting bolts and disconnect the LED/matrix wiring harness.

Warnings

Tools required

Parts

• Headlight assembly (LH or RH, matrix LED, Model S Plaid 2024) × 1 — Tesla OEM headlight assembly — match by VIN, side, and trim
• Replacement plastic push-pin retainers (fascia/liner) × 1 — Generic Tesla fascia clip kit — replace any broken on disassembly

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. Open the frunk and disconnect the 12V (or 16V Li-ion on applicable Plaid units, located under the rear seat) low-voltage battery negative terminal. Torque on reinstall: see Battery Terminal Bolts 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. Place soft fender covers over the front fender and hood edge to protect the aluminum paint.
7. Turn the steering wheel toward the side being serviced and chock the rear wheels before lifting the front if wheel arch liner removal is needed.
8. Identify which headlight (LH/RH) is being replaced and confirm the replacement assembly matches by VIN.

Procedure

1. 1

   Access the headlight area
   Open the frunk. Remove the frunk weatherstrip along the upper edge of the fascia on the affected side, then remove the upper trim/cowl fasteners using a plastic trim tool. On the Model S refresh/Plaid, the upper fascia trim must be released to expose the upper headlight mounting tab.
   ⚠Use only plastic trim tools — metal pry bars will gouge aluminum panels and painted plastic.
2. 2

   Remove wheel arch liner fasteners (if required for access)
   Turn the wheels to expose the front wheel arch liner. Remove the forward push-pins and Torx fasteners securing the liner to the fascia. Pull the liner back enough to access the lower outboard headlight bolt and the side bracket fastener.
3. 3

   Release the front fascia (partial)
   Remove the fasteners along the upper edge of the fascia and the inner-fender tabs on the affected side. Carefully pull the fascia outboard a few centimeters to release the side clips — only enough to access the headlight outboard mounting bolt. Do not yank; the fascia houses sensors and harnesses.
   ⚠The front fascia contains parking sensors, ambient temperature sensor, and possibly camera/radar harnesses. Do not pull the fascia fully off without disconnecting these connectors first.
4. 4

   Disconnect headlight electrical connector
   Locate the main headlight harness connector at the rear of the assembly. Depress the locking tab and disconnect. Inspect the connector and pins for corrosion or damage; do not pull on the wires.
5. 5

   Remove headlight assembly mounting bolts
   Remove the headlight mounting bolts (typically three: one upper, one inboard, one outboard/lower) using the appropriate Torx or 10mm socket. Support the assembly with one hand as the last bolt is removed so it does not fall against the fascia or fender.
   Torque spec

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

   Remove the headlight assembly
   Lift the headlight straight out of its locating pins. Inspect the mounting tabs and any rubber isolators for damage. If a tab is broken on the new assembly side, the manufacturer-specified bracket/repair kit must be used — refer to Tesla Service Manual.
   ⚠Headlight housings on the refresh Model S have integrated plastic mounting tabs that crack easily. Do not pry against them.
7. 7

   Transfer any reusable hardware to new assembly
   If the replacement assembly does not include adjuster hardware or bracketry, transfer them from the old unit. Verify all locating pins are present and undamaged on the new assembly.
   Torque spec

   Adjuster Screws3 Nm (2 lb-ft)
8. 8

   Install the new headlight assembly
   Seat the new headlight onto its locating pins, ensuring the assembly sits flush with the fender and hood gap. Hand-thread all mounting bolts before torquing any of them, to allow alignment.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Torque mounting bolts and reconnect harness
   Torque the headlight mounting bolts to spec in a cross-pattern (upper, inboard, outboard). Reconnect the main harness connector and confirm the locking tab clicks home.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)

   Connector Screws4 Nm (3 lb-ft)
10. 10

    Reinstall fascia, liner, and trim
    Reseat the fascia onto its side clips, ensuring all sensor/camera connectors are reconnected. Reinstall the wheel arch liner fasteners and the upper frunk trim. Replace any push-pins that broke during disassembly.

Reassembly

1. Verify hood-to-headlight and fender-to-headlight panel gaps are even on both sides; adjust assembly position before final torque if needed.
2. Reinstall the frunk weatherstrip, ensuring it seats fully along the fascia edge.
3. Reconnect the 12V/16V low-voltage battery negative terminal and torque to the Battery Terminal Bolts spec.
4. Close the frunk and verify the latch engages properly (the latch sensor sits adjacent to the headlight area and can be disturbed during service).

Verification

• Power up the vehicle. Check for any headlight, ADAS, or matrix-LED related fault messages on the center display.
• Test low beam, high beam, turn signal, DRL, and cornering/adaptive functions on the replaced side. Compare beam pattern and color to the unaffected side.
• Perform a short test drive at night or against a wall: confirm matrix/adaptive functions activate and aim is correct. If the vehicle reports an adaptive headlight calibration fault, the assembly will require configuration via Tesla service tooling at a Tesla Service Center.
• Recheck panel gaps after a few drive cycles — fascia clips can settle.
• Note: This job does not affect Tesla's published service intervals, but if the 12V was disconnected for an extended period, verify date/time and driver profile settings restored correctly.

More procedures for this vehicle