Replace both headlight assemblies on the 2024 Tesla Roadster (Tri Motor AWD). Note: this vehicle shares limited service documentation; verify mounting hardware and connector routing against the Tesla Service Manual before beginning.

Warnings

Tools required

Parts

• Headlight assembly, left (driver side) × 1 — OEM Tesla Roadster (2024) LH headlamp assembly — verify against VIN
• Headlight assembly, right (passenger side) × 1 — OEM Tesla Roadster (2024) RH headlamp assembly — verify against VIN
• Replacement plastic retainer clips × 6 — Manufacturer-specified front fascia/headlight clips (have spares — original clips often break on removal)

Preparation

1. Park on level ground, place in P, engage 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 (or 16V/48V on applicable models) low-voltage battery. Refer to the Tesla Service Manual for the exact battery location on the 2024 Roadster — it is not in the same location as Model S/3/X/Y.
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 the vehicle was recently driven — LED housings and internal heatsinks can retain heat.
7. Place soft covers over the front fenders and hood edge to prevent paint damage.
8. Photograph all connector routing and clip locations before disassembly — this vehicle has limited published reference material.
9. Have the replacement headlight assemblies on hand and inspected for shipping damage before removing the originals.

Procedure

1. 1

   Confirm low-voltage system is de-energized
   After disconnecting the low-voltage battery, attempt to operate the headlights via the stalk/touchscreen (if accessible). They should not respond. This confirms the lighting circuit is dead before unplugging connectors.
2. 2

   Access the headlight mounting area
   Remove any front fascia trim, wheel arch liner edge fasteners, or upper grille/cowl panels required to expose the headlight mounting bolts and rear connectors. Use plastic trim tools to release clips. Set all fasteners aside in a labeled tray — fastener types may differ between left and right sides.
   ⚠Do not pry against painted surfaces. Lift clips straight out to avoid breaking the retainer barbs.
3. 3

   Disconnect the headlight wiring harness (driver side)
   Locate the main electrical connector at the rear of the LH headlight assembly. Depress the locking tab fully and pull the connector straight off — do not pull on the wires. If the housing has a secondary connector for adaptive/matrix functions or DRL, disconnect that as well. Cap or tape the connectors to keep contacts clean.
4. 4

   Remove the driver-side headlight mounting fasteners
   Remove the bolts/screws securing the LH headlight assembly to the front structure. Support the assembly with one hand as the last fastener is removed so it does not fall forward into the bumper or fender.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Remove the driver-side headlight assembly
   Carefully pull the LH headlight forward and out of its locating tabs. If it does not move freely, recheck for a hidden fastener or clip — DO NOT force it. Place the removed assembly lens-up on a padded surface.
   ⚠Aluminum body — do not pry against the fender edge. Limited service info exists for this model; verify all retainers are released before pulling.
6. 6

   Disconnect the passenger-side headlight wiring harness
   Repeat the connector disconnect procedure for the RH side. Note any differences in connector count or routing between sides (e.g., washer hose, ambient sensor lead).
7. 7

   Remove the passenger-side headlight mounting fasteners and assembly
   Remove the RH mounting fasteners and lift the assembly out the same way as the LH side. Inspect the now-exposed mounting points for any damaged threads, bent brackets, or corroded ground points.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Inspect and prepare the new headlight assemblies
   Compare the new LH and RH assemblies to the originals — confirm matching connector keying, mounting tab geometry, and any leveling/AFS motor presence. Transfer over any reusable brackets or rubber bushings only if the new units do not include them. Confirm headlight aim adjusters are at their nominal/center position.
9. 9

   Install the driver-side headlight assembly
   Position the new LH assembly into its locating tabs and slide it rearward until fully seated. Hand-start all mounting fasteners before torquing any of them — this prevents misalignment with the fender and hood gaps.
   Torque spec

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

    Torque the driver-side mounting fasteners
    Once the assembly is correctly aligned with the surrounding bodywork, torque the mounting fasteners in a cross pattern to the specification listed.
    ⚠If the listed Mounting Bolts torque does not match the fastener size you encounter, STOP and verify the correct torque from the Tesla Service Manual before proceeding.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect the driver-side electrical connectors
    Plug the main and any secondary connectors into the LH headlight until the locking tabs click. Tug gently on each connector body to confirm full engagement. Route harnesses back through their original retainers — do not allow wires to rest against the housing's heatsink fins.
12. 12

    Install the passenger-side headlight assembly
    Repeat steps 9–11 for the RH side: position, hand-start fasteners, align with bodywork, torque mounting fasteners, then reconnect electrical connectors.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
13. 13

    Verify panel gaps before reinstalling trim
    With both headlights bolted in but trim still off, sight along the hood-to-headlight and fender-to-headlight gaps from the front and side. They should be even left-to-right. If not, loosen the offending side and re-seat before continuing.

Reassembly

1. Reinstall any front fascia trim, grille panels, wheel arch liner fasteners, or cowl pieces removed for access. Replace any clips that broke during removal.
2. For any reused trim screws or bracket bolts encountered, torque per the Bracket Bolts or Cover Screws specification as appropriate, or to OEM specification — refer to Tesla Service Manual if unsure.
3. Reconnect the low-voltage battery, observing terminal polarity. Torque the terminal hardware to the Battery Terminal Bolts specification. Do not overtighten.
4. Allow the vehicle to wake and complete its low-voltage power-up sequence (typically 30–60 seconds) before testing systems.

Verification

• Power on the vehicle and check the touchscreen for any new fault messages related to lighting, AFS/matrix beam, or auto-high-beam.
• Cycle through low beam, high beam, DRL, and turn signal functions on both sides. Confirm each LED segment illuminates as expected — matrix/adaptive units should not have dark segments.
• If the vehicle has adaptive front lighting (AFS/matrix beam), drive at low speed in a safe area and confirm the steering-correlated beam articulation works on both sides. Some Tesla vehicles require a service-tool calibration after headlight replacement; if any AFS-related warning appears, the assemblies will need to be coded/calibrated by a Tesla-certified technician.
• Perform a headlight aim check against a target board or wall at the manufacturer-specified distance. Adjust using the housing's aim screws to bring beam cutoff to spec.
• Inspect for water intrusion after the first wash or rain — confirm both housings are sealed at the lens and the rear access cover.
• Note: this job is not part of a scheduled Tesla service interval, but while the front end is exposed, it is a good opportunity to inspect the cabin air filter (Tesla recommends replacement every 2 years) and verify washer fluid level (system capacity ~3.5 qt).

More procedures for this vehicle