Polestar Car Parts UK - Quality Used & Genuine Parts

How to Replace Polestar Headlights

Polestar headlight replacement requires care due to sophisticated LED technology and premium components. Whether replacing standard LED units or upgrading Thor's Hammer signature headlights, this guide covers Polestar 2, 3, and 4 models built on Volvo and Geely platforms.

Step-by-Step Instructions:

1. Open the bonnet and secure it with the prop rod. Locate the rear of the headlight assembly from within the frunk area. On Polestar 2 models sharing Volvo CMA platform architecture with XC40 Recharge, access is relatively straightforward with good clearance to the headlight mountings. On Polestar 3 and 4 models built on Geely's SEA platform, the higher bonnet line provides excellent access to headlight components. Ensure the vehicle is completely powered off before beginning work on electrical components.
2. Disconnect all electrical connectors carefully. Polestar headlights typically have 2-4 electrical connectors depending on specification and technology level. Modern Polestar models include LED daytime running lights with distinctive Thor's Hammer design, main beam, dipped beam, side lights, and on models with adaptive LED headlights additional connectors for cornering lights and automatic leveling systems. Press the release tabs gently and pull straight out. Handle all connectors with extreme care as replacement electrical components for electric vehicles are expensive and Polestar parts availability can be limited due to relatively low production volumes compared to mainstream brands.
3. Remove the headlight mounting bolts systematically. Most Polestar models use T25 or T30 Torx screws to secure the headlight assembly following Volvo engineering standards. On Polestar 2 models, there are typically 3-4 bolts along the top edge easily accessible once the bonnet is open. On Polestar 3 SUV models, expect 4 main mounting bolts with clear access from above due to higher ride height. Polestar 4 models have similar mounting arrangements. Remove all mounting bolts completely and place them in a container to avoid losing these precision fasteners which may need ordering from Sweden if lost.
4. Release any additional clips or retainers present. Some Polestar headlights use supplementary plastic clips at various points for additional security and precise alignment maintaining tight panel gaps. On Polestar 2 models, check for clips at the inner corner near the blanked-off Smartzone grille area. On Polestar 3 and 4 models, look for clips at the bottom edge. Work carefully as clips can become brittle with age especially on early Polestar 2 models from 2020-2021, and replacement clips for Polestar models may require ordering from specialist suppliers or Volvo parts networks.
5. Carefully remove the headlight assembly from the vehicle. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. Polestar headlights slide forward on precision locating pins that ensure correct alignment and even panel gaps maintaining Scandinavian design aesthetic. Support the weight as you pull to prevent dropping, as Polestar headlights contain sophisticated LED technology and cost hundreds or thousands of pounds to replace depending on specification. If you feel any resistance, stop immediately and check for missed fixings rather than forcing, as damaging the mounting points will require expensive bodywork repairs on premium electric vehicles.
6. Transfer components to new headlight if required. If your replacement headlight doesn't include LED modules, leveling motors, or adaptive lighting components, carefully transfer these from the old unit. When handling any LED components, wear clean gloves to avoid touching LED modules or lens surfaces with bare hands, as oils and contaminants cause premature failure and reduced light output. For adaptive LED systems with Thor's Hammer daytime running signature, handle the electronic modules with particular care as they are extremely expensive to replace and may have limited availability.
7. Install the new headlight assembly with precision. Reverse the removal process by aligning the new headlight with mounting pins and push firmly into place ensuring all locating pins engage correctly and panel gaps are even maintaining Polestar's minimalist design aesthetic. Refit all mounting bolts and tighten securely but do not overtighten as this can crack mounting points on composite materials. Reconnect all electrical connections ensuring each clicks firmly into place. Before final assembly, power on the vehicle and test all lighting functions including dipped beam, main beam, daytime running lights with Thor's Hammer signature, side lights, and indicators. Check adaptive functions if fitted. Verify headlight alignment using adjustment mechanisms on the rear of the assembly.

Important Notes: Polestar headlight replacement is straightforward but requires care due to expensive LED components and limited parts availability. Never touch LED modules or lens surfaces with bare hands. Adaptive LED headlights may require coding to the vehicle using Volvo VIDA diagnostic software to avoid warning lights and ensure full functionality, as Polestar vehicles share diagnostic protocols with Volvo. Proper headlight alignment is crucial for optimal visibility and MOT compliance in the UK. If replacing only one headlight, consider the age of the existing headlight as LED output degrades over time and mismatched light output may be noticeable. Genuine Polestar or Volvo OEM headlights ensure perfect fit and finish maintaining the vehicle's premium appearance and resale value in the growing electric vehicle market.

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How to Replace Polestar Front Bumper

Replacing a Polestar front bumper is achievable in 45-90 minutes depending on model and familiarity with electric vehicle components. This process covers Polestar 2, 3, and 4 models, though specific screw locations and sensor configurations vary between generations and trim levels.

Step-by-Step Instructions:

1. Open the bonnet and secure it with the prop rod safely. Locate the upper bumper mounting fixings along the top edge just below the Smartzone blanked-off grille area. Most Polestar models have 6-8 Torx screws or bolts securing the bumper along the top edge. On Polestar 2 models, these are typically T25 Torx screws easily accessible once the bonnet is open. On Polestar 3 and 4 SUV models, expect 6-8 fixings across the top. Remove all upper fixings systematically and place them in a container. Ensure the vehicle is completely powered off before working near electric vehicle components.
2. Access the wheel arch areas on both sides carefully. Turn the steering wheel fully left to access the right side wheel arch, then fully right for the left side. Behind each front wheel, locate the plastic wheel arch liner. Remove or release 3-5 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. Polestar uses Volvo-style plastic push-in clips that release by pressing the center pin first, then removing the entire clip. Some models also use Torx screws. Work carefully as arch liners are expensive to replace on electric vehicles. Repeat the process on both sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-4 screws or bolts securing each side of the bumper to the wing and chassis. These are usually T25 or T30 Torx screws on Polestar models following Volvo standards. Remove all side fixings on both driver and passenger sides. Keep track of which fixings came from which side if they differ in length or type, as Polestar uses precise fasteners for specific locations maintaining structural integrity important for electric vehicle crash safety.
4. Remove undertray screws and lower bumper fixings systematically. Get underneath the vehicle safely using proper ramps or jack stands, ensuring the vehicle is secure. Electric vehicles are heavy due to battery packs so use appropriate equipment. Locate and remove all screws and clips securing the undertray and lower edge of the bumper. Polestar typically uses 8-12 fixings along the bottom edge depending on model. These may be Torx screws or plastic push-in clips. Work systematically from one side to the other. You may need to partially lower the undertray for better access.
5. Disconnect parking sensors, cameras, and all electrical connections. Reach behind the bumper and disconnect all electrical connectors including parking sensor connections which Polestar models have as standard equipment typically with 4 sensors in the front bumper, front cameras if equipped with 360-degree camera systems or Pilot Assist driver assistance technology on newer models, and any additional connections for radar systems used for adaptive cruise control and collision avoidance systems. Press release tabs carefully and pull straight out. Count how many connections you disconnect and note their positions, as electric vehicle sensor systems are sophisticated and all must be reconnected correctly during refitting to avoid warning lights and system malfunctions.
6. Release the bumper side clips and mounting tabs carefully. Polestar bumpers are secured by plastic clips or brackets on each side that slot into the wing panels and chassis mounting points. With all fixings removed, firmly but gently pull the bumper forward from one corner while supporting the opposite side. You may need to wiggle slightly to release the side clips. Listen for clicks as clips disengage. Work patiently as forcing can break expensive clips or damage mounting points requiring costly repairs on premium electric vehicles with aluminum and composite construction.
7. Remove the bumper completely from the vehicle with care. With all fixings removed and clips released, carefully pull the bumper straight forward away from the vehicle. Polestar bumpers are reasonably sized but contain sensor brackets and mounting hardware. Having a second person is helpful especially on Polestar 3 and 4 SUV models with larger bumpers. Place the removed bumper on a protected surface such as a thick blanket to avoid scratching the painted surface or damaging the lower lip which is exposed on the low-slung Polestar 2.
8. Prepare and fit the replacement bumper assembly precisely. Before installation, transfer any brackets, trim pieces, parking sensors, or mounting components from the old bumper if not fitted to your replacement. Check that all sensors are correctly installed and secure. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly and the bumper sits flush with the wings. Reconnect all electrical connections including parking sensors and cameras, ensuring each connector clicks firmly. Systematically secure with all screws and clips in reverse order of removal. Before final assembly, power on the vehicle and test all electrical functions including parking sensors by having someone walk around the front while you sit inside, and cameras if fitted. Check panel gaps are even on both sides maintaining Polestar's precise Scandinavian design aesthetic. Adjust if necessary using the mounting points before final tightening.

Top Tips: Polestar bumpers are designed for practical replacement but require care due to integrated sensors and cameras. When refitting parking sensors, ensure each sensor clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface, as even minor misalignment can cause false warnings on electric vehicles with sensitive systems. On models with front-mounted cameras or radar for Pilot Assist adaptive cruise control and active safety systems, these may require recalibration at a Polestar specialist or Volvo-certified facility after bumper replacement using VIDA diagnostic software. Check all panel gaps between bumper and wings are even before final tightening, as Polestar's Scandinavian design philosophy emphasizes precise panel fit and clean lines. Test all parking sensors thoroughly by having someone walk around the front of the vehicle while you sit inside, ensuring each sensor detects objects correctly without false warnings. If any sensor warnings appear, verify all electrical connections are secure and sensors are clean and properly aligned. Genuine Polestar or Volvo OEM bumpers ensure perfect panel fit and maintain the vehicle's premium appearance and resale value in the competitive electric vehicle market.

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Common Polestar Parts Problems & Solutions

Polestar vehicles represent Scandinavian design excellence meeting Chinese manufacturing efficiency as an independent electric vehicle brand jointly owned by Volvo and Geely. Built in China to be sold worldwide, Polestar combines Swedish premium knowhow with ambitious Chinese production capabilities. The brand ranked 2nd overall in Auto Express Driver Power 2023 survey showing strong owner satisfaction, and Polestar 2 achieved 89.3% reliability rating in What Car? 2024 survey ranking 10th out of 20 electric cars. However, certain components experience specific issues particularly on early production vehicles. Here are the most commonly reported Polestar parts problems based on verified data from UK owners, mechanics, What Car? surveys, and specialist forums.

TCAM Module Failures (Polestar 2) - Most Common and Serious Issue:

• What is TCAM and Why It Matters: TCAM stands for Telematics and Connectivity Antenna Module, the device that houses and controls various connectivity radios inside Polestar vehicles. The TCAM handles all networking and communication features including LTE cellular data connectivity, GPS navigation signals, digital key functionality allowing phone-as-key operation, Polestar app connectivity for remote climate control and charging management, SOS eCall emergency calling system, and over-the-air software updates essential for keeping the vehicle current. When the TCAM fails, it can render multiple critical systems inoperable simultaneously making this the most significant reliability concern for Polestar 2 owners.
• Symptoms and Severity of TCAM Failures: TCAM failures manifest in various ways with severity ranging from inconvenient to completely disabling. Loss of LTE connectivity means no internet for navigation streaming or app functions. GPS navigation becomes completely inoperable or shows incorrect location jumping erratically on the map. Digital key stops working leaving owners unable to unlock or start the vehicle using their phone, requiring physical key fob. Key fob recognition fails completely with car not responding to physical keys, leaving owners locked out and stranded. SOS eCall emergency system becomes unavailable creating safety concerns. Polestar app loses connection preventing remote vehicle control. Over-the-air updates cannot be received requiring manual updates at dealerships. In the most severe cases reported by multiple owners, TCAM failures have left people completely locked out of their vehicles unable to access or drive the car, requiring roadside assistance and towing.
• Prevalence and Affected Models: TCAM issues primarily affect Polestar 2 models from 2020-2022 model years though later models can also experience problems. While Polestar states only a small percentage of vehicles are affected, owner forums and NHTSA complaints show hundreds of reports making this a well-documented issue. Multiple owners report repeated TCAM failures requiring multiple dealer visits without permanent resolution. One owner reported throwing in the towel after four dealership visits without satisfactory fix. The issue is serious enough that Polestar issued Service Action S1013 for 2021-2022 Polestar 2 models addressing digital certificate issues preventing over-the-air updates.
• Root Causes: Several factors contribute to TCAM failures. Software bugs in TCAM firmware cause system crashes or freezes. Digital certificate issues prevent proper authentication and updates. Water leaks through the shark fin antenna on the roof cause physical damage to the TCAM module, with multiple owners reporting this specific failure mode. TCAM backup battery drainage occurs when the 3.6V backup battery powering the TCAM depletes, often correlated with charging to 100% or leaving car on charger for extended periods which may interrupt the routine charging sequence. Some failures occur immediately after over-the-air software updates suggesting update-related bugs.
• Temporary Fixes and Workarounds: Several temporary solutions can restore TCAM functionality though they don't address root causes. TCAM reset procedure involves holding the front defroster button for 15-20 seconds until the SOS light flashes red, which reboots the TCAM system and works in many cases. Infotainment reboot by holding the home button for 15 seconds can resolve some connectivity issues. Simply waiting several hours or even days sometimes allows the system to recover on its own for reasons unknown. The most reliable temporary fix is the 12V and TCAM battery disconnect procedure which requires accessing the 12V battery in the frunk and the TCAM 3.6V backup battery hidden behind trim in the driver side rear C-pillar, disconnecting both, waiting several minutes, then reconnecting to perform complete power cycle. Detailed instructions are available on Polestar forums though the process is frustrating and time-consuming.
• Permanent Solutions and Costs: For persistent TCAM issues, dealerships perform several permanent fixes. Software updates using Volvo VIDA diagnostic system address firmware bugs and certificate issues, typically completed free under warranty. TCAM module replacement is necessary when hardware has failed, with the module costing approximately £500-£1,200 plus labor. Shark fin antenna replacement or resealing fixes water ingress issues costing £200-£500. Outside warranty, repairs can be expensive. Polestar has released multiple over-the-air updates including version 2.4 and later attempting to resolve TCAM reliability, with fewer complaints reported since software version 2.2 onwards suggesting improvements though not complete elimination of issues.
• Prevention and Recommendations: To minimize TCAM problems, keep vehicle software updated to latest version through over-the-air updates or dealer updates. If experiencing connectivity loss preventing OTA updates, visit dealer for manual update. Check shark fin antenna periodically for proper sealing especially after car washes. Avoid leaving vehicle on charger at 100% for extended periods as this correlates with TCAM battery drain. Learn the TCAM reset and battery disconnect procedures as many Polestar 2 owners keep necessary tools in the vehicle for emergency resets. When buying used Polestar 2 from 2020-2022, verify TCAM service history and whether module has been replaced or updated. Enable phone-as-key forgotten on your phone as backup access method though this also relies on TCAM functioning. Despite improvements, TCAM reliability remains a concern for potential Polestar 2 buyers especially earlier models.

12V Battery Drain and Vehicle Bricking (Polestar 2):

• Hidden 12V Battery Issues: Polestar 2 has a small 12V auxiliary battery hidden near the boot area that powers critical vehicle systems even when the main high-voltage battery is disconnected. When this 12V battery fully discharges, it cripples the entire car preventing starting, unlocking, or any functionality, effectively bricking the vehicle. Multiple owners report being stranded due to 12V battery drain. The 12V battery is recharged by the main battery through a DC-DC converter, but various issues can prevent proper charging leading to drain.
• Symptoms and Causes: Complete inability to unlock or start vehicle, all systems dead, key fobs not recognized, and no response from any controls indicate 12V battery failure. Causes include parasitic drain from various systems continuing to draw power when parked, TCAM issues causing abnormal power consumption, extended periods without driving allowing natural battery discharge, and in some cases faulty DC-DC converter failing to maintain 12V battery charge from main battery. Some bricking incidents occur while vehicle is plugged in charging the main battery but 12V system fails.
• Solutions: Jump starting the 12V battery in the frunk restores basic functionality allowing access to vehicle. The 12V battery may need replacement if damaged from deep discharge, costing £150-£300. Investigating and fixing underlying causes of drain is essential to prevent recurrence. Installing a battery monitor that tracks 12V battery voltage via Bluetooth helps owners monitor battery health and predict failures before they occur. These devices cost £20-£30 and are increasingly popular among Polestar 2 owners as preventative measure.

Infotainment System Glitches (All Models):

• Android Automotive OS Issues: Polestar vehicles use Google-based Android Automotive OS with 11.1-inch portrait touchscreen on Polestar 2 and larger screens on newer models. While praised for smooth functionality and frequent over-the-air updates, the system experiences recurring glitches. What Car? 2024 survey identified sat-nav and infotainment as creating the biggest headache for Polestar 2 owners with 42% reporting issues.
• Common Problems: Touchscreen freezing or becoming completely unresponsive requiring reboot, audio system suddenly stopping with no sound from speakers, turn signals, or parking sensors creating safety concerns, system resets occurring randomly during driving, Apple CarPlay connectivity issues despite over-the-air updates adding enhanced CarPlay support, slow response times and lag when interacting with touchscreen, and climate control adjustments requiring touchscreen interaction becoming impossible during freezes. The thick bezels on Polestar 2's screen give it a dated appearance compared to newer competitors.
• Fixes: Infotainment reboot by holding home button for 15 seconds resolves most temporary freezes and is a procedure many owners perform regularly. Software updates from Polestar address bugs and improve stability, so keeping system updated is essential. Some issues require dealer intervention with more comprehensive software reflashing using VIDA diagnostic system. Two-thirds of repairs in What Car? survey were completed in a day or less and all were fixed free under warranty showing good dealer support despite recurring nature of issues.

Propulsion System Errors and Limp Mode (Polestar 2):

• Serious Powertrain Warnings: Multiple Polestar 2 owners report Propulsion System Service Required warnings appearing on the dashboard, sometimes accompanied by vehicle entering limp mode with severely limited power or complete loss of propulsion. Some vehicles refuse to move at all requiring towing. Other cases show warning but car drives normally though with occasional jerking and stuttering. In some fortunate cases, turning off the vehicle and waiting allows the error to clear and normal operation to resume.
• Causes and Repairs: Propulsion system errors stem from several sources. High voltage battery disconnect unit failures can interrupt power flow. Inverter or power electronics faults cause loss of motor control. Software bugs in battery energy control module cause internal resets that temporarily disable propulsion. Recalls have addressed some issues including internal BECM resets causing high voltage connectors to open during driving. Repairs typically involve software updates, replacing high voltage battery disconnect unit, or replacing inverter or motor control electronics. These components are covered by 8-year or 100,000-mile EV powertrain warranty in UK, extended to 10 years or 150,000 miles in California.

Front Suspension Knocking and Clunking (Polestar 2):

• Suspension Noise Issues: Owners notice knocking or clunking noises from front suspension especially during braking or on uneven surfaces. The noises are distracting and raise concerns about suspension component failures. Polestar forum members discussed a service bulletin issued to replace strut bearings with upgraded parts addressing the problem.
• Solution: Dealers replace affected strut bearings with improved upgraded components typically covered under warranty for affected vehicles. If buying used Polestar 2, listen carefully during test drives for suspension noises and have seller address issues before purchase. The firm ride quality on Polestar 2 compared to competitors like BMW 3 Series can make suspension noises more noticeable.

Backup Camera Problems (Polestar 2):

• Poor Camera Quality and Functionality: Common complaint among Polestar 2 owners is the backup camera's poor image quality with low resolution making it difficult to see obstacles clearly. Camera takes several seconds to display image especially if car has been sitting overnight. Image can switch on and off intermittently while backing up. Error messages saying camera unavailable appear frequently. Camera automatically turns off when vehicle stops moving for a few seconds requiring repeated button presses to reactivate, which is frustrating during parking maneuvers.
• Solutions: Cleaning the camera lens improves image quality somewhat but doesn't address fundamental resolution limitations. Infotainment reboot sometimes helps with camera delays and error messages. Software updates have improved camera reliability though issues persist. Recall was issued for rear-facing camera failures on some models. The camera quality remains a weak point compared to competitors with better camera systems.

Antenna Module Faults (Polestar 2):

• Connectivity Hardware Failures: Separate from TCAM software issues, the physical antenna module connecting car to internet can fail. This module provides LTE connectivity to Polestar service centers enabling functions like app control, eCall emergency services, GPS navigation, and digital key operation. When antenna module fails, these functions stop working creating similar symptoms to TCAM failures.
• Fix: Dealers replace faulty antenna module which typically resolves issues permanently. Many owners report that module replacement solved recurring connectivity problems where software updates and TCAM resets had failed. This suggests some connectivity issues are hardware failures rather than software bugs. Replacement is covered under warranty for affected vehicles.

Recalls Affecting Polestar Vehicles:

• UK Recall Summary: Polestar 2 has had five recalls in the UK addressing various safety and functionality issues. Battery pack tin plating defect could cause short circuit and fire risk. High voltage connectors to battery could disconnect while driving causing motors to stall and complete loss of propulsion. Front suspension joint could come loose creating crash risk. Rear-facing camera failure affects visibility. Loss of braking performance in one-pedal driving mode reduces stopping ability. All recalls should have been addressed on affected vehicles through Volvo or Polestar dealerships free of charge. When buying used Polestar, verify all recalls completed by contacting Polestar customer support with VIN.

Polestar Reliability Assessment:

Mixed but Improving Reliability Picture: Polestar reliability data shows mixed results reflecting young brand still developing production quality and software maturity. Polestar brand ranked 2nd overall in Auto Express Driver Power 2023 showing strong owner satisfaction with the ownership experience. However, Polestar 2 individual model ranked 71st in reliability with 69% of first-year owners reporting faults showing teething problems on new model. What Car? 2024 survey ranked Polestar 2 with 89.3% reliability placing 10th out of 20 electric cars, above Kia EV6 and Porsche Taycan but below Tesla Model 3. As a brand, Polestar ranked 23rd out of 31 manufacturers with 89.3% score, less reliable than Hyundai, Kia, and Tesla but beating Audi and MG.

42% Fault Rate with Good Dealer Support: What Car? survey found 42% of Polestar 2 owners reported issues with their cars, a high percentage, but most were fixed swiftly at no cost to owners showing good warranty support. Infotainment and TCAM connectivity created biggest headaches followed by 12V battery and electrical systems. Two-thirds of repairs completed in a day or less showing responsive dealer network. All repairs completed free under warranty demonstrating Polestar stands behind products despite early quality issues.

Software-Heavy Problems: Most common Polestar issues are software-related rather than mechanical failures, including TCAM connectivity bugs, infotainment glitches, and propulsion system software errors. This suggests reliability will improve through software updates and maturity as brand gains experience with over-the-air update capabilities. Hardware issues like suspension noise and camera quality show some traditional manufacturing challenges remain.

Newer Models Too Early to Assess: Polestar 3 launched 2024 and Polestar 4 even more recently lack sufficient reliability data for comprehensive assessment. Initial owner feedback on Polestar 3 reports excellent build quality and refinement suggesting lessons learned from Polestar 2 production. Polestar 4's controversial no-rear-window design using cameras remains unproven in long-term use. Both models built on newer Geely SEA platform rather than Volvo CMA platform used for Polestar 2 so reliability may differ significantly.

Prevention and Smart Ownership Recommendations: To maximize Polestar reliability, keep vehicle software updated through over-the-air updates or dealer visits ensuring latest bug fixes and improvements are installed. Learn TCAM reset and 12V battery disconnect procedures keeping necessary tools in vehicle for emergency resets which many Polestar 2 owners consider essential. When buying used Polestar 2, prioritize 2023+ facelift models with updated software and hardware improvements over earlier 2020-2022 models with higher fault rates. Verify all recalls completed and check TCAM module replacement history. Consider extended warranty for out-of-warranty vehicles given 42% fault rate. Monitor 12V battery health using inexpensive Bluetooth battery monitors as preventative measure. Despite issues, many owners report loving their Polestar vehicles for design, performance, and driving experience once software bugs are resolved. The 3-year or 60,000-mile warranty and 8-year or 100,000-mile EV powertrain warranty provide good coverage during ownership period when most faults occur and are fixed free. Polestar represents exciting Swedish-Chinese collaboration bringing fresh approach to electric vehicle market with room for improvement as brand matures.

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