Citroen Van Parts UK - Quality Used & Genuine Parts

How to Replace Citroen Van Headlights

Citroen van headlight replacement is straightforward on Berlingo, Dispatch, and Relay models. Whether replacing standard units or upgrading to LED headlights, this guide covers the complete Citroen van range including electric models.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely with the prop rod. Locate the rear of the headlight assembly from within the engine bay. On Berlingo models, access is excellent with plenty of working space around the compact engine. On Dispatch and Relay models, the larger bonnet opening provides comfortable access to headlight mountings. Electric e-Berlingo, e-Dispatch, and e-Relay models have even better access due to simplified electric drivetrain layout with no traditional engine components blocking access.
2. Disconnect all electrical connectors from the headlight. Citroen van headlights typically have 2-3 electrical connectors depending on specification. These include main beam connector, dipped beam connector, and side light connector. On models with daytime running lights there may be an additional DRL connector. Press the release tabs on each connector carefully and pull straight out to disconnect. Handle connectors gently as the plastic clips can become brittle with age especially on high-mileage commercial vehicles.
3. Remove the headlight mounting bolts and screws. Most Citroen van models use T20 or T25 Torx screws to secure the headlight assembly to the front panel. On Berlingo models, there are typically 2-3 bolts along the top edge of the headlight easily accessible once the bonnet is open. On Dispatch and Relay models, expect 3-4 mounting bolts with clear access from above. Remove all mounting bolts completely and keep them organized for refitting. Some models may use a combination of Torx screws and 10mm bolts depending on production year.
4. Release any additional clips or retaining tabs. Some Citroen van headlights use supplementary plastic clips at various points for additional security and alignment. On Berlingo models, check for clips at the inner corner near the grille. On Dispatch and Relay models, look for clips at the bottom edge of the headlight assembly. Work the clips carefully using a trim removal tool as they can become brittle with age and exposure to heat from the engine bay.
5. Carefully remove the headlight assembly from the van. With all bolts, screws, and clips released, gently pull the headlight straight forward out of its mounting position. Citroen van headlights slide forward on locating pins that ensure correct alignment when refitting. Support the weight of the headlight as you pull to prevent dropping it. If you feel any resistance, stop immediately and check for missed fixings rather than forcing the headlight out which could damage mounting points or the headlight itself.
6. Transfer components to new headlight if required. If your replacement headlight doesn't include bulbs or additional components, carefully transfer these from the old unit to the new one. When handling bulbs, always wear clean gloves to avoid touching glass surfaces with bare hands as skin oils cause premature bulb failure and hot spots. For halogen bulbs, never touch the glass. LED and bulb types vary by model and trim level so ensure correct bulbs are fitted.
7. Install the new headlight assembly into the van. Reverse the removal process by aligning the new headlight with the locating pins on the front panel and push firmly into place ensuring all pins engage correctly in their mounting holes. Refit all mounting bolts, screws, and clips in the reverse order of removal and tighten securely. Reconnect all electrical connections ensuring each clicks firmly into place. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and indicators to confirm everything works correctly.

Important Notes: Citroen van headlight replacement is a straightforward DIY job on most models. When handling new headlights, never touch lens or reflector surfaces as fingerprints and oils affect light output. After fitting new headlights, check beam alignment using adjustment screws on the rear of the assembly. Proper headlight alignment is crucial for optimal visibility, preventing dazzling oncoming drivers, and ensuring MOT compliance. Most Citroen vans have headlight adjustment screws accessible from the engine bay without removing the headlight.

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How to Replace Citroen Van Front Bumper

Replacing a Citroen van front bumper is achievable in 45-90 minutes depending on model and experience level. This process covers Berlingo, Dispatch, and Relay models, though specific screw locations and fixing methods vary between generations and body sizes.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely with the prop rod. Locate the upper bumper mounting fixings along the top edge just below the grille and radiator assembly. Most Citroen van models have 4-8 Torx screws or bolts securing the top edge of the bumper. On Berlingo models, these are typically T20 or T25 Torx screws clearly visible once the bonnet is open. On Dispatch and Relay models, expect 6-10 fixings across the top depending on bumper width and generation. Remove all upper fixings systematically working from one side to the other.
2. Access the wheel arch areas on both sides of the van. Turn the steering wheel fully to one side to maximize access to the wheel arch liner behind the front wheel. Behind each front wheel, locate the plastic arch liner that protects the inner wing. Remove or release 2-4 plastic clips or screws securing the front section of the arch liner to expose the side bumper mounting points. Citroen vans typically use plastic push-in clips that release by pressing the center pin first before pulling the entire clip out. Repeat the process on both driver and passenger sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner that you've pulled back, you'll find 2-4 screws or bolts securing each side of the front bumper to the wing and chassis. These are usually T20 or T25 Torx screws on most Citroen van models. Remove all side fixings on both driver and passenger sides completely. Keep track of which fixings came from which location if they differ in size or length as this makes refitting easier and ensures correct reassembly.
4. Remove undertray screws and lower bumper fixings. Get underneath the van safely using ramps, axle stands, or a vehicle lift. Locate and remove all screws and clips securing the engine undertray and the lower edge of the front bumper. Citroen vans typically use 6-12 fixings along the bottom edge of the bumper. These may be Torx screws, plastic push-in clips, or a combination of both. On Berlingo models the undertray is relatively small and easy to access. On Dispatch and Relay models the undertray is larger but fixings remain accessible. You don't always need to remove the entire undertray, just the front section securing the bumper.
5. Disconnect fog lights, sensors, and any electrical connections. Reach behind the bumper and disconnect all electrical connectors carefully. This includes fog light connections if your van is fitted with fog lights, parking sensor connections if equipped with parking assist (common on higher spec Dispatch and Relay models), and any additional connections for cameras or radar on newer vans with driver assistance systems. Press the release tabs on each connector carefully and pull straight out. Count how many electrical connections you disconnect to ensure you reconnect them all during refitting and avoid leaving any disconnected.
6. Release the bumper side clips and mounting tabs. Citroen van bumpers are secured by plastic clips or metal brackets on each side that slot into the wing panels and chassis rails. With all screws, bolts, and clips removed, firmly but gently pull the bumper forward from one corner while a helper supports the opposite side. You may need to wiggle the bumper slightly side to side to release the clips. Listen for clicks as the clips disengage from their mounting points. Work carefully to avoid breaking clips or damaging mounting points on the wings.
7. Remove the bumper completely from the van. With all fixings removed and all clips released, carefully pull the front bumper straight forward away from the van. Citroen van bumpers are reasonably lightweight on Berlingo models allowing one person to manage removal. Dispatch and Relay bumpers are larger and heavier due to increased width and may benefit from a second person to support the weight and prevent dropping. Place the removed bumper on a protected surface such as cardboard or blankets to avoid scratching the painted surface during storage.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, number plate mounts, or components from the old bumper to your replacement if they're not already fitted. Align the new bumper with the van's mounting points and push firmly into place ensuring all side clips engage properly into the wing panels. Reconnect all electrical connections including fog lights and parking sensors ensuring each clicks firmly. Systematically secure the bumper with all screws and clips in reverse order of removal, starting with side fixings then top fixings and finally undertray fixings. Test all electrical functions including fog lights and parking sensors before final assembly to confirm everything works. Check all panel gaps between bumper and wings are even on both sides and adjust if necessary before final tightening.

Top Tips: Citroen van bumpers are designed for practical replacement to minimize downtime for commercial operators. When refitting parking sensors if equipped, ensure each sensor clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface to prevent false warnings. On electric e-Berlingo, e-Dispatch, and e-Relay models, some bumpers may house charging port covers or additional cooling vents for battery thermal management, so check these components transfer correctly to replacement bumpers. Check all panel gaps between the bumper and wings are even on both sides before final tightening of fixings. Citroen's manufacturing tolerances mean replacement parts typically fit well without extensive adjustment, though minor tweaking of clip positions may be needed for perfect alignment.

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Common Citroen Van Parts Problems & Solutions

Citroen vans are known for dependability and value for commercial users. The Berlingo ranked fifth most reliable van in the FN50 2018 survey and won International Van of the Year 2019, while Dispatch proved its durability with one example running 315,000 miles requiring only one clutch replacement. Citroen backs their commercial vehicles with a 100,000-mile warranty demonstrating confidence in build quality. However, certain components can experience specific issues based on verified data from UK owners, mechanics, and commercial fleet operators. Here are the most commonly reported Citroen van parts problems.

Water Ingress into Fuse Box (Berlingo - Most Common Issue):

• Most Frequently Reported Berlingo Problem: Water getting into the fuse box is the most common issue reported by Berlingo owners and garages. The fuse box on Citroen Berlingo models is located in a position vulnerable to water ingress, particularly from windscreen washer bottle overflow or condensation. When water enters the fuse box, it causes electrical faults that can affect various systems including lights, wipers, central locking, and dashboard electronics. Symptoms include intermittent electrical problems, blown fuses, warning lights on the dashboard, and systems cutting out unexpectedly.
• Repair Cost and Solution: Fortunately this is a relatively low-cost repair to fix. Repair costs typically range from £80-£200 depending on the extent of water damage and which fuses or relays need replacing. The solution involves drying out the fuse box completely, replacing any damaged fuses or corroded connectors, and sealing the fuse box properly to prevent future water ingress. Some specialists recommend relocating the fuse box or improving drainage around the affected area. Regular inspection of the fuse box for moisture and ensuring proper sealing can prevent this common problem from recurring.

1.6 HDi Turbo Failure (First-Generation Models):

• Engine Turbo Problems on Early Diesel Models: First-generation Citroen Berlingo models fitted with the 1.6 HDi diesel engine suffered from premature turbo failure, though this issue has been corrected on later models from 2018 onwards. The 1.6 HDi engine requires owners to use high-quality engine oil and adhere strictly to service intervals. Failure to use the correct specification oil or extending service intervals beyond recommendations led to turbo failure in many instances. This problem wasn't isolated to Citroen and affected various manufacturers using similar engines as they balanced fuel economy targets with low emissions requirements.
• Prevention and Costs: If buying a used 1.6 HDi Berlingo, it's essential to check for full service history with evidence of regular oil changes using the correct specification oil. Vans with over 100,000 miles may have already required turbo replacement as this is one of the most common Citroen Berlingo problems on early models. Turbo replacement costs vary but typically range from £600-£1,500 depending on whether genuine or aftermarket parts are fitted and labour rates. Later generation Berlingos from 2018 onwards with improved engines and the third-generation model have eliminated this turbo issue through better engine design and component quality.

Central Locking Electrical Wiring Issues (Berlingo):

• Faulty Door Lock and Wiring Problems: Central locking faults are a common problem affecting many Citroen Berlingo vans. The issue stems from electrical wiring problems affecting the central locking system. Typical symptoms include the key fob making the lights flash when pressed but failing to lock or unlock the driver's door, intermittent operation where locking works sometimes but not others, and complete failure of central locking requiring manual locking with the key. The root cause is often broken wires in the wiring harness that runs through the rubber gutter between the driver's door and the van's body.
• Diagnosis and Repair: While this should theoretically be an easy fix, owners and garages often struggle to identify the exact cause of the problem due to intermittent faults and multiple potential failure points. The first step is to check for broken or damaged wires in the wiring harness running through the rubber gutter between the driver's door and body as this is the most common failure point due to constant flexing when opening and closing the door. Inspect all visible wiring for signs of damage, fraying, corrosion, or breaks. Repair costs depend on the extent of wiring damage but typically range from £100-£400 for diagnosis and repair including replacement of damaged sections of wiring harness.

ABS Pump Failure (Berlingo 2014-2023):

• ABS and Braking System Faults: The Citroen Berlingo from 2014-2023 is affected by a common ABS fault that causes the ABS warning light to remain illuminated on the dashboard. The faulty ABS pump and module results in brake problems including binding or locking of one or more wheels, imbalanced braking with the van pulling to one side when brakes are applied, inconsistent brake pedal feel, and loss of ABS-assisted braking forcing drivers to rely on standard braking until the fault is rectified. In certain cases, the ABS light is accompanied by the traction control warning light indicating further failure of the ABS pump and module.
• Safety Concerns and Repair: If the ABS light is illuminated in your Berlingo, this is a clear indication of a failing ABS system and should be acted upon immediately as it affects vehicle safety. Common failing part numbers include 0265956416/2265106516, 0265956353/2265106481, and 0265956240/9808055980. Standard manufacturer response is to replace the complete ABS pump and module with a new unit which is expensive. However, specialist companies offer test and rebuild services for Citroen Berlingo ABS units replacing commonly failing internal components with higher-rated parts, offering unlimited mileage lifetime warranties, and returning rebuilt units within 2-3 working days at lower cost than new replacement.

Relay Drop Link Wear (After 20,000 Miles):

• Suspension Component Replacement: The Citroen Relay has a robust reliability record overall, however one known recurring issue is that the drop links connecting the anti-roll bar to the suspension wishbone can wear out and require replacement after approximately 20,000 miles. This is higher wear than typical for commercial vehicles and represents a maintenance item that Relay owners should anticipate. Symptoms of worn drop links include clunking noises from the front suspension when driving over bumps, rattling sounds from the suspension area, and reduced handling stability.
• Affordable Repair: Fortunately drop link replacement is both affordable and straightforward, making this a minor inconvenience rather than a major problem. Replacement drop links cost approximately £20-£50 per side for quality aftermarket parts, with labour adding £80-£150 depending on garage rates. Many competent DIY mechanics can replace drop links themselves in 30-60 minutes with basic tools. Regular inspection of drop links and replacement when wear is detected prevents the issue from affecting vehicle safety or causing damage to other suspension components.

Starting Issues and Fuel System Problems (Various Models):

• Engine Starting and Running Difficulties: Starting issues are relatively common across Citroen van models especially on higher mileage examples. Once obvious causes like a dead battery have been eliminated, deeper investigation is required. There's no single issue causing starting problems as multiple systems can be involved. If you hear a clicking sound when attempting to start the van, this typically indicates a starter motor problem. Starter motors on commercial vans often fail under 100,000 miles because of continual start-stop operation inherent to delivery and service work. If you don't hear a clicking sound when turning the key, the problem is more likely a clogged fuel filter preventing adequate fuel delivery to the engine. A blocked fuel filter can also cause a noticeable drop in performance or intermittent running issues.
• Diagnosis and Repair Costs: Starter motor replacement costs typically range from £150-£400 depending on model and whether genuine or aftermarket parts are fitted. Fuel filter replacement is much cheaper at £30-£80 including labour and is a regular maintenance item that should be performed according to service schedules. Some owners of older 2.2 HDi Relay models have reported starting and running issues with these engines, though these cases are relatively rare and later 2.0 BlueHDi engines from 2016 onwards have proven more reliable.

Power Steering Vibration and Air Contamination (Berlingo):

• Steering System Problems: Some Citroen Berlingo owners have reported vibration from the steering wheel that isn't caused by wheel imbalance. The actual cause is air contamination in the power steering system. Air in the power steering fluid causes the system to work intermittently, setting up vibrations felt through the steering wheel particularly at low speeds or when stationary. This can be concerning for drivers as it suggests a potential safety issue with steering components.
• Solution and Prevention: The solution is to remove all the old power steering fluid and replace it with fresh fluid, then bleed the system completely to remove all trapped air. This typically costs £60-£120 at a garage including fluid and labour. The procedure involves draining the old fluid, refilling with new power steering fluid to the correct specification, and bleeding the system by turning the steering wheel lock to lock multiple times with the engine running until all air bubbles are expelled. Regular power steering fluid changes help prevent contamination and maintain smooth steering operation.

EGR Valve Failure and Limp Mode (Diesel Models):

• Engine Performance and Limp-Home Mode: Citroen vans can suddenly drop into limp-home mode where engine performance is severely restricted. This is typically indicated by sluggish acceleration, significantly reduced power output, and the engine warning light illuminated on the dashboard. The most common cause is a faulty EGR (Exhaust Gas Recirculation) valve that has become clogged with carbon deposits or failed mechanically. The EGR valve recirculates exhaust gases back into the engine to reduce emissions, but over time carbon buildup restricts valve operation.
• Diagnosis and Repair: Connecting a diagnostic fault code reader to the van's OBD socket will typically display EGR-related fault codes confirming the problem. EGR valve replacement costs vary by model but typically range from £150-£400 for the part plus £100-£200 labour. Some specialists offer EGR valve cleaning services for £80-£150 which can restore function without full replacement, though severely damaged or worn valves require replacement. Regular use of diesel fuel system cleaners and avoiding excessive short journeys that don't allow the engine to reach full operating temperature can help reduce EGR carbon buildup and extend valve life.

Cooling Fan Control Unit Failure (Berlingo):

• Engine Overheating Issues: Some Berlingo owners experience engine overheating that's not caused by coolant leaks or thermostat problems. The actual fault lies with the cooling fan control unit or resistor that regulates fan speed. When this component fails, the cooling fan doesn't operate correctly leading to insufficient cooling especially in traffic or hot weather. Diagnostic fault code readers will typically display codes P0483 or P0118 when the fan is inoperative.
• Simple Replacement: Once diagnosed, replacing the cooling fan control unit or resistor is relatively straightforward. The part costs approximately £40-£100 depending on model, with labour adding £50-£100 at a garage. Many DIY mechanics can replace this component themselves in 30-60 minutes following workshop manual instructions. After replacement, the cooling system should be checked for leaks and topped up with coolant to the correct level, and the cooling fan operation should be tested to confirm it runs at various speeds according to engine temperature.

Gearbox and Transmission Issues (Relay Models):

• Difficult Gear Selection: Some Citroen Relay models, particularly 2003-2006 examples, experience gearbox problems including difficulty selecting first, second, or reverse gears, gear linkage wear causing imprecise gear selection, and in severe cases complete loss of certain gears requiring gearbox removal and repair or replacement. The gear change can become very difficult especially when selecting lower gears from a standstill. Initial problems may start with worn or poorly lubricated gear linkages which can be improved temporarily with lubrication, but often internal gearbox wear is the underlying cause.
• Repair Costs and Options: If gear linkages are the problem, adjustment or replacement costs £100-£250. However, if internal gearbox faults are confirmed, complete gearbox removal is required. Most people opt to replace the gearbox with a remanufactured or good used unit rather than strip and repair the original as labour costs for gearbox rebuild are extremely high. Replacement gearbox costs vary from £400-£800 for a good used unit plus £400-£800 labour for fitting, or £800-£1,500 for a remanufactured gearbox with warranty. Regular gearbox oil changes every 40,000-60,000 miles help prevent premature wear and extend gearbox life.

Citroen Van Reliability Assessment:

Overall Good Reliability with Known Issues: Citroen vans offer dependable service for commercial operators with good build quality and durability proven over decades of production. The Berlingo has been one of Europe's best-selling vans since 1996, won International Van of the Year 2019, and ranked fifth most reliable van in the FN50 2018 survey based on real-world fleet data. The Dispatch demonstrated exceptional durability with one example running 315,000 miles requiring only one clutch replacement according to RAC surveys. Citroen backs their commercial vehicles with a 100,000-mile warranty showing confidence in reliability. The prevalence of older Citroen vans still actively used on UK roads speaks to their enduring build quality and longevity.

Common Issues Are Manageable: While the problems listed above are the most commonly reported by owners and mechanics, most are relatively minor and affordable to repair. Water ingress to the fuse box on Berlingo is the single most common issue but costs only £80-£200 to resolve. First-generation Berlingo 1.6 HDi turbo problems have been eliminated on later models from 2018 onwards. Drop link replacement on Relay after 20,000 miles is a known maintenance item that's both affordable and straightforward. Most electrical and starting issues can be diagnosed and repaired for reasonable costs. The key to maximizing Citroen van reliability is maintaining regular service intervals, using correct specification fluids and parts, and addressing problems promptly before they escalate.

Prevention and Maintenance: To maximize reliability of your Citroen van, follow these recommendations. Adhere strictly to Citroen service schedules particularly for oil changes on diesel engines. For 1.6 HDi models use only high-quality oil meeting Citroen specifications. Regularly inspect the fuse box on Berlingo models for signs of moisture and ensure proper sealing. Check ABS pump operation and address any warning lights immediately as braking safety is critical. Inspect drop links on Relay models every 20,000 miles and replace when worn. Use quality diesel fuel and fuel system cleaners to prevent EGR valve carbon buildup. Address starting issues promptly before they leave you stranded. When buying used Citroen vans, prioritize examples with full service history, verify all known issues have been addressed, and have pre-purchase inspections performed. Despite known issues, Citroen vans remain popular commercial choices offering good reliability, low running costs, and practical functionality that keeps businesses operating efficiently.

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