I have noticed a gap around the headlamp seal, and there isn’t any obvious way to adjust it. The lens is properly installed on the removable unit, is there some other adjustment that can be made to the mount or something?

 

...difficult too tell from that photo, but are you sure the headlight unit is seated properly?

What happenes when you operate the lever that ejects the headlight? How far out does it move?

 

It seems to be seated correctly, the lever is down and the connectors engage so that the lights work. It won't push in any further.

 

Are the lens or housing tabs fully inserted?

 

Hi Gabi,
After responding to the above, I suspect the pod mounting track has some adjustment ability.
Andy

 

Is this the metal track in the bottom of the opening?

 

Hi Gabi,
Yes, its fasteners may be able to be loosened a little and the track moved slightly
Before doing this spray a little silicone or Teflon lube on the track and put some on your finger and rub it on the electrical plug seal.
This may help fully seat the headlight pod.
Please report back here with your outcomes.
Andy

 

Thank you, I'll take some photos while attempting this and report back!

 

More than likely it is the plastic one on the side which attaches to the frunk side of the inner fender. The bolts are right next to the rod which locks/unlocks the headlight housing.

Given the gap seems to be isolated to the one side, I'd suspect it is the plastic track on that side. That is what controls how far the headlight inserts and where it locks in place. The metal ones on the bottom are likely not at play.

 

The guide doesn’t seem to be adjustable. The bolts only anchor the plastic “holder” clip for the release arem.

 

Silly question but have you tried flipping the handle up instead of down to lock?