Replace the headlight assembly on a 2012 Tesla Roadster. Because the Roadster shares its chassis with the Lotus Elise/Exige, the headlight assemblies and mounting hardware are largely Lotus-sourced and accessed from behind the front clamshell wheel-arch liner area.

Warnings

Tools required

Parts

• Headlight assembly (Roadster-specific, Lotus-based housing) × 1 — Manufacturer-specified Tesla Roadster headlight assembly — verify left vs right
• Replacement fasteners / clips (as needed if damaged on removal) × 1 — OEM specification

Preparation

1. TESLA SAFETY PREAMBLE: Park on level ground, place transmission in neutral or first gear (manual gearbox on early Roadsters), and engage the parking brake firmly. Chock the rear wheels.
2. Exit all doors with the key fob away from the vehicle. Wait at least 2 minutes for any HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 12V low-voltage battery. On the Roadster the 12V auxiliary battery is located in the front trunk/frunk area — remove the cover and disconnect the negative terminal first.
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. Identify which side (LH/RH) headlight assembly is being replaced and confirm the replacement part matches.
7. Have the front of the vehicle clear and well-lit; access for the Roadster headlight is tight due to the low front clamshell.

Procedure

1. 1

   Access the rear of the headlight assembly
   Open the front trunk/service access. Depending on assembly orientation, access to the headlight rear may be from the engine/frunk bay or from inside the front wheel arch via the inner liner. If wheel-arch access is required, turn the wheel to the opposite side, remove the inner fender liner fasteners, and fold the liner aside to expose the headlight backshell.
   ⚠Do not pull the front clamshell or painted body away from the chassis — composite panels crack easily.
2. 2

   Disconnect headlight wiring
   Locate the main electrical connector(s) on the rear of the headlight assembly (low/high beam, turn signal, position lamp, and any leveling motor connector if equipped). Release the locking tab on each connector and unplug. Note connector orientation for reassembly.
3. 3

   Disconnect headlight ground (if separate)
   If the assembly has a dedicated ground strap to the chassis, remove the bolt. Clean both contact surfaces (chassis stud and strap eyelet) before reinstallation to ensure a low-resistance connection.
   ℹ️Poor ground contact will cause flickering or dim lamps — clean to bare metal.
   Torque spec

   Ground Strap Bolt14 Nm (10 lb-ft)
4. 4

   Remove headlight assembly mounting bolts
   Locate the headlight assembly mounting bolts securing the housing to the front sub-frame/clamshell support bracket. There are typically three to four bolts per side. Support the assembly with one hand while removing the final bolt.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
5. 5

   Remove the headlight assembly
   Carefully withdraw the headlight assembly forward/outward from its mounting pocket. Watch for any remaining harness routing clips. Place the old assembly on a padded surface lens-up.
   ⚠Do not let the lens contact the painted clamshell during removal — masking tape on adjacent paint is recommended.
6. 6

   Transfer bulbs/components if required
   If the new assembly is supplied bare, transfer bulbs, leveling motor, and any rubber covers from the old assembly. Handle halogen bulbs only by the metal base — skin oils on the glass shorten bulb life.
7. 7

   Install new headlight assembly
   Position the new assembly into its mounting pocket, aligning the mounting tabs with the chassis bracket holes. Hand-thread all mounting bolts before final torquing to avoid cross-threading. Torque to specification.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
8. 8

   Reconnect ground and electrical connectors
   Reinstall the ground strap bolt with clean contacts and torque to spec. Reconnect each electrical connector until the locking tab clicks. Verify connectors are fully seated — partial seating causes intermittent lamp failure.
   Torque spec

   Ground Strap Bolt14 Nm (10 lb-ft)
9. 9

   Preliminary aim check
   Headlight aim adjuster screws are accessed from the rear of the housing. Do not over-torque the plastic adjuster screws. Make only fine corrections at this stage; full aim alignment will be done after the vehicle is reassembled and on level ground.
   ⚠Adjuster screws thread into plastic — exceeding torque will strip the housing.
   Torque spec

   Adjuster Screws3 Nm (2 lb-ft)

Reassembly

1. Reinstall the inner fender liner and any clips removed for access.
2. Reconnect the 12V battery negative terminal last; torque the battery terminal bolt to specification.
3. Close the frunk and confirm latch engagement.
4. Cycle the headlight switch through all positions (parking, low beam, high beam, turn signal) and verify correct operation.
5. Perform headlight beam aim adjustment against a wall at the manufacturer-specified distance, using the adjuster screws.

Verification

• Visually confirm both headlights illuminate evenly with no flicker — flickering indicates a poor ground or unseated connector.
• Verify high/low beam switching works from the stalk and the dash high-beam indicator illuminates.
• Confirm turn signal and position lamps function (if integrated into the headlight assembly).
• Check beam pattern on a flat wall — cutoff should be sharp and even side-to-side. Adjust via the adjuster screws if needed (torque to spec).
• Confirm no warning chimes or instrument cluster lamp-out indicators on initial drive.
• Inspect for water tightness after the next rain or wash — a foggy lens indicates a failed seal.

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