Replace both headlight assemblies on a 2012 Tesla Roadster. Because the Roadster shares its front clamshell and lighting architecture with the Lotus Elise/Exige, headlight access is via the front clamshell area and wheel-well liners rather than any Tesla-specific service panel.

Warnings

Tools required

Parts

• Headlight assembly, left (driver) — Roadster-specific OEM unit × 1 — Manufacturer-specified Roadster 2.x headlight assembly, LH
• Headlight assembly, right (passenger) — Roadster-specific OEM unit × 1 — Manufacturer-specified Roadster 2.x headlight assembly, RH
• Replacement plastic trim clips/fasteners (as needed) × 1 — Generic clamshell/wheel-liner clip set

Preparation

1. Park on level ground, place transmission in neutral or park as applicable, and firmly engage the parking brake. Chock the rear wheels.
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 auxiliary battery before working on any lighting circuit. On the 2012 Roadster the 12V auxiliary battery is located in the front compartment area — refer to the owner/service manual for exact location on your build.
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. Allow the headlights to cool fully if they have recently been on.
7. Turn the steering to full lock on each side as needed to access wheel-well liner fasteners.
8. Lay out soft blankets or fender covers along the front clamshell edges to protect paint.

Procedure

1. 1

   Gain access to headlight mounting fasteners
   Remove the front wheel-well liner fasteners on both sides as required to access the rear of the headlight housings. The Roadster uses a Lotus-style combination of plastic push clips and small machine screws. Carefully fold or remove the liner enough to reach the headlight backshell.
   ⚠Composite clamshell edges chip easily — protect with tape before pulling liners away.
2. 2

   Remove headlight cover/trim (if equipped)
   If your Roadster is fitted with the clear headlight covers or any retaining trim ring, remove the perimeter fasteners and lift the cover off. Set on a soft surface, inside-up, to protect the lens.
3. 3

   Disconnect headlight electrical connectors
   Unplug the low-beam, high-beam, turn signal/DRL, and any leveling motor or position-light connectors at the rear of the headlight assembly. Depress the locking tabs — do not pull on the wires. Inspect connectors for corrosion or heat damage and note any pin discoloration.
   ℹ️Roadster harnesses are aged — connector locking tabs become brittle. Work them gently.
4. 4

   Release the headlight assembly retaining hardware
   Locate the headlight assembly mounting fasteners (typically a combination of bolts at the top of the assembly into the clamshell crossmember and at the rear into the chassis bracket). Support the assembly with one hand while removing the last fastener so it does not drop into the front fascia.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
5. 5

   Remove the driver-side headlight assembly
   With all fasteners and connectors free, lift the LH headlight assembly straight out of its opening. Tilt slightly to clear any locating pegs at the front edge. Place the old unit lens-down on a clean cloth.
6. 6

   Remove the passenger-side headlight assembly
   Repeat steps 1–5 on the RH side. Compare both removed assemblies side-by-side with the new units to confirm correct fitment, connector orientation, and any transferable hardware (bulbs, leveling motors, mounting tabs).
7. 7

   Transfer hardware to new assemblies (if required)
   If the new headlights are supplied bare, transfer bulbs, bulb covers, leveling motors, and mounting brackets from the original assemblies. Use clean gloves when handling halogen/HID bulbs to avoid skin oils on the glass.
   ⚠If the assembly contains an HID ballast, ensure the 12V battery has remained disconnected before unplugging it.
8. 8

   Install the new driver-side headlight assembly
   Position the new LH assembly into the opening, engaging any front locating pegs first, then bring the rear bracket into alignment. Start all mounting fasteners by hand before tightening any of them. Torque the bracket bolts to specification.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Install the new passenger-side headlight assembly
   Repeat the installation procedure on the RH side. Confirm even gap and flush alignment with the surrounding clamshell on both sides before final torque.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect all headlight connectors until each locking tab clicks fully home. Route harnesses away from sharp composite edges and any moving suspension/steering components. If any connector uses retaining screws, torque to the connector screw specification.
    Torque spec

    Connector Screws4 Nm (3 lb-ft)
11. 11

    Reinstall wheel-well liners and any covers
    Reinstall fender liners and headlight covers/trim using new clips where the originals are damaged. Do not overtighten fasteners into composite — they strip easily.
12. 12

    Reconnect the 12V battery
    Reconnect the 12V auxiliary battery negative terminal last. Torque the battery terminal bolts to specification — do not overtighten.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all clamshell-area fasteners and clips are seated and torqued.
2. Confirm wheel-well liners are fully reinstalled with no contact against the tire at full lock.
3. Tidy and secure any harness sections that were repositioned during the job.

Verification

• With the 12V reconnected, power on the vehicle and cycle: low beams, high beams, parking/position lights, turn signals, and (if equipped) DRLs on both sides.
• Check for any dash warning lights related to lighting; the Roadster's VDS may report bulb-out faults if a connector is not fully seated.
• Park 25 ft (7.6 m) from a flat wall on level ground and verify headlight aim. Adjust using the assembly's aim screws so low-beam cutoff is at the correct height per the Tesla Roadster service manual or general FMVSS guidance.
• Drive at low speed and confirm no rattles from the front clamshell area.
• Note: this job is unrelated to scheduled service intervals, but while the front of the car is open it is a good time to inspect the 12V battery (typical 3–5 year life) and washer fluid level (system capacity ~3.5 qt) and to plan brake fluid service if it has been more than 2 years.

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