Hyundai Van Parts UK - Quality Used & Genuine Parts

How to Replace Hyundai Van Headlights

Hyundai van headlight replacement is straightforward on Staria, i800, and iLoad models. Whether replacing damaged units or upgrading to improved bulbs, this guide covers all Hyundai commercial vehicles.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the rear of the headlight assembly from within the engine bay. On iLoad models, access is straightforward with good clearance. On i800 models, the layout is identical to iLoad. On Staria models, the futuristic front-end design provides clear access to headlight mountings despite the striking exterior styling. Ensure the engine is cool before starting work.
2. Disconnect all electrical connectors. Hyundai van headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. Press the release tabs carefully on each connector and pull straight out. On Staria models with LED technology, handle connectors with particular care as LED control modules are integrated. Keep track of which connector goes where by taking a photo before disconnection.
3. Remove the headlight mounting bolts. Most Hyundai van models use 10mm bolts to secure the headlight assembly. On iLoad and i800 models, there are typically 3-4 bolts along the top and side edges easily accessible once the bonnet is open. On Staria 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 have additional plastic clips providing supplementary security.
4. Release any additional clips or retainers. Some Hyundai van headlights use supplementary plastic clips at various points for additional security. On iLoad and i800 models, check for clips at the inner corner near the grille. On Staria models with the distinctive front-end design, look for clips at the bottom edge. Work carefully as plastic clips can become brittle with age especially on older iLoad models. If clips break during removal, replacement clips are available from Hyundai parts suppliers.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. Hyundai headlights slide forward on locating pins that ensure correct alignment during installation. Support the weight as you pull to prevent dropping the unit. If you feel resistance, stop and check for missed fixings rather than forcing. On Staria models, the headlight units are larger due to the extended LED strip design so take extra care during removal.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs or LED modules, carefully transfer these from the old unit. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as oils cause premature bulb failure. On Staria LED headlights, LED modules are typically integrated and cannot be transferred, so ensure your replacement includes all necessary components.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and push firmly into place ensuring all locating pins engage correctly. Refit all mounting bolts and tighten securely but avoid overtightening which can crack plastic mounting points. Reconnect all electrical connections ensuring each clicks firmly. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and indicators. Check headlight alignment visually and adjust if necessary using adjustment screws on the rear of the assembly.

Important Notes: Hyundai van headlight replacement is straightforward on all models. When handling new headlights, never touch lens or reflector surfaces as fingerprints reduce light output. On Staria models with advanced LED technology, the distinctive horizontal LED strip is the defining design feature so ensure replacement units match your specification. Proper headlight alignment is crucial for optimal visibility and MOT compliance. If headlights seem misaligned after fitting, visit a garage with headlight alignment equipment for professional adjustment.

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How to Replace Hyundai Van Front Bumper

Replacing a Hyundai van front bumper is achievable in 60-90 minutes depending on model. This process covers Staria, i800, and iLoad models, though specific fixing locations vary between generations.

Step-by-Step Instructions:

1. Open the bonnet and secure it with the prop rod. Locate the upper bumper mounting fixings along the top edge just below the grille area. Most Hyundai van models have 4-6 bolts or screws securing the top of the bumper. On iLoad and i800 models, these are typically 10mm bolts or Phillips screws. On Staria models with the futuristic grille design, expect 6-8 fixings across the top edge. Remove all upper fixings systematically and store them safely.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to one side to maximize access to the wheel arch liner. Behind each front wheel, locate the plastic arch liner. Remove or release 2-4 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. Hyundai vans typically use plastic push-in clips that release by pressing the center pin first, then pulling the entire clip out. Repeat on both driver and passenger sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-3 screws or bolts securing each side of the bumper. These are usually 10mm bolts or Phillips screws on Hyundai van models. 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. On commercial van variants, additional support brackets may be present.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Locate and remove all screws and clips securing the engine undertray and lower edge of the bumper. Hyundai vans typically use 6-10 fixings along the bottom edge. These may be 10mm bolts, Phillips screws, or plastic push-in clips. You don't always need to remove the entire undertray, just enough fixings to release the bumper. On iLoad and i800 models, pay attention to any tow bar mounting points if fitted.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors including fog lights if fitted, parking sensor connections if equipped with parking assist (standard on Staria models), and any additional connections for cameras or radar on newer Staria models with advanced safety systems. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting. On Staria models, the advanced safety systems require multiple sensor connections.
6. Release the bumper side clips and mounting tabs. Hyundai van bumpers are secured by plastic clips or metal brackets on each side that slot into the wing panels. 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 clips. Listen for clicks as clips disengage. On Staria models, the large bumper with distinctive styling may require a second person for safe removal.
7. Remove the bumper completely from the vehicle. With all fixings removed and clips released, carefully pull the bumper straight forward away from the vehicle. Hyundai van bumpers are substantial on commercial models so consider getting a second person to help especially with iLoad and Staria models. Place the removed bumper on a protected surface like cardboard or old blankets to avoid scratching the painted surface.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, fog light assemblies, or sensor components from the old bumper if not fitted to your replacement. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly. Reconnect all electrical connections including fog lights, parking sensors, and safety system sensors on Staria models. Systematically secure with all screws, bolts, and clips in reverse order of removal. Test all electrical functions before final assembly including fog lights and parking sensors. Check panel gaps are even on both sides and bumper alignment is correct. On Staria models with advanced safety systems, ensure all sensors are clicking firmly into their mounting positions and are correctly aligned.

Top Tips: Hyundai van bumpers are designed for practical replacement especially on commercial iLoad models. When refitting parking sensors, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. On Staria models with front-mounted cameras or radar for collision avoidance systems, these may require recalibration at a Hyundai specialist after bumper replacement to ensure safety systems function correctly. Check all panel gaps between bumper and wings are even before final tightening. On commercial iLoad variants, ensure any tow bar mountings are correctly aligned if fitted.

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Common Hyundai Van Parts Problems & Solutions

Hyundai commercial vans are renowned for solid build quality and robust reliability. The brand ranked third in the 2024-2025 J.D. Power Initial Quality Study, demonstrating excellent manufacturing standards. The iLoad established an excellent reputation over a decade (2007-2021) building strong customer loyalty in commercial sectors. However, certain components can experience specific issues. Here are the most commonly reported Hyundai van parts problems based on verified data from UK owners, mechanics, and industry specialists.

Turbocharger Failures (iLoad and i800) - Most Common Issue:

• The Problem: Turbocharger failure is the most frequently reported issue on iLoad and i800 models with the 2.5-litre CRDi diesel engine. Multiple owners report turbos failing repeatedly, with some experiencing 2-3 turbo failures on the same vehicle. The turbo can fail catastrophically causing complete loss of power and potentially causing engine damage if debris enters the intake system. This is particularly common on higher-mileage examples but has occurred on relatively low-mileage vehicles as well.
• Root Cause: The primary cause is oil starvation to the turbocharger bearings due to blocked or restricted oil feed lines. The narrow oilway feeding lubricating oil to the turbo bearing is prone to becoming blocked by sludge buildup in the engine, particularly on vehicles not serviced at correct intervals. When oil supply is interrupted even briefly, the turbo bearings overheat and fail. Another contributing factor is the black death phenomenon where diesel soot from the EGR system mixes with oil mist creating thick black gunk in the intake manifold and breather system, which can contaminate oil and block oilways.
• Warning Signs: Loss of power especially under acceleration or when loaded, high-pitched whining or whistling noise from the turbo area particularly under boost, blue or black smoke from the exhaust indicating oil burning or incomplete combustion, oil leaks from turbo area especially from seals, and check engine light illuminated with boost pressure codes. If you notice any of these symptoms, have the vehicle inspected immediately by a Hyundai specialist as continued driving will cause complete turbo failure and potentially catastrophic engine damage.
• Prevention and Solutions: The critical prevention measure is maintaining strict service intervals of maximum 10,000km or 6 months rather than Hyundai's recommended 15,000km intervals. Commercial vans get a hard life and need more frequent oil changes to prevent sludge buildup. Always use high-quality fully synthetic diesel oil meeting Hyundai specifications. When replacing a failed turbo, the oil feed line must be thoroughly cleaned or replaced, the oil must be changed, and the intake system should be cleaned of black death deposits to prevent repeat failure. Simply fitting a new turbo without addressing the root cause will result in another failure within a short period. Many mechanics recommend preventative intake manifold cleaning every 50,000km to remove carbon and sludge deposits. Turbo replacement costs range from £800-£1,800 depending on whether genuine or aftermarket turbo is fitted plus labor.

Fuel Injector Problems (iLoad and i800):

• The Problem: Fuel injectors on the 2.5-litre CRDi diesel engine are prone to corroding onto the cylinder head making removal extremely difficult. This occurs when copper sealing washers at the base of the injector that seal against the head leak, allowing compression and combustion gases to escape up into the cylinder head. The leaking seals also allow diesel and combustion particles into the oil in the head, creating very sludgy oil. Symptoms include excessive fuel consumption, rough running, black smoke from the exhaust indicating overfuelling, and loss of power.
• Root Cause and Solution: The injector sealing washers (copper washers) fail due to heat cycling and compression forces over time. Investigation of failed engines has found 3 out of 4 injector seals leaking significantly. This leakage allows compression to escape and increases combustion particles going into the engine oil, accelerating sludge formation which then blocks turbo oil feeds creating a cascading failure pattern. When replacing injectors, new copper sealing washers must always be fitted and torqued to correct specifications. Attempting to reuse old washers will result in immediate leakage and repeat problems. Injector replacement costs range from £600-£1,200 for parts and labor depending on how corroded the injectors are onto the head.

Coolant System Issues (iLoad and i800):

• Overheating Problems: Multiple owners report coolant system issues including overheating, coolant being pushed into the overflow tank but not being drawn back in when cool, and coolant loss requiring frequent topping up. Some vehicles push out approximately 1 litre of coolant on a 3-hour run even with no visible leaks and no overheating occurring. Common causes include radiator cap failure not maintaining correct pressure, thermostat failure or incorrect installation (thermostats installed backwards stop coolant flow), water pump failure, and head gasket problems on poorly maintained examples.
• Warning Signs and Solutions: Temperature gauge rising above normal, coolant overflow tank constantly full with coolant being expelled, steam or coolant smell from engine bay, and heater not working properly. When experiencing coolant issues, first replace the radiator cap as this is the cheapest fix. Check the thermostat is installed correctly facing the right direction as incorrect installation is surprisingly common and prevents proper coolant circulation. If these simple fixes don't resolve the issue, investigate water pump, radiator, and head gasket. Regular coolant system maintenance including flush and refill every 2 years helps prevent issues. Repair costs range from £50 for a radiator cap to £800-£1,500 for head gasket replacement if the problem has progressed.

Sliding Door Mechanism Failures (i800 and iLoad Crew):

• December 2018 Recall: Hyundai issued a recall affecting 1,173 units of iMax and iLoad vehicles manufactured in 2018 for a faulty rear sliding door locking mechanism that can fail. The door may not lock properly creating a safety risk of the door opening while driving. Beyond the recall, many owners report challenges with opening and closing sliding doors often attributed to dirt accumulation in the door track. This is generally preventable with regular cleaning and maintenance including lubricating the track and rollers.
• Prevention: Regularly clean sliding door tracks removing dirt, dust, hair, and debris that can jam mechanisms. Lubricate door rollers and tracks every few months with appropriate lubricant. Inspect door alignment ensuring the door sits correctly in its frame. Address any stiffness or unusual noises immediately before they develop into complete failure. On Staria models with powered sliding doors, electrical glitches can cause random beeping and jerking though this is typically a software issue rather than mechanical failure.

Black Death - Intake Manifold Sludge (iLoad and i800 Diesel):

• The Problem: Modern turbo-diesel engines including the iLoad's 2.5-litre CRDi are prone to black death, a buildup of thick black gunk in the intake system. This results from diesel soot and oil mist mixing as part of the vehicle's emissions control systems. The EGR (Exhaust Gas Recirculation) system recirculates exhaust gases back through the intake, and when this combines with oil vapor from the crankcase breather, it creates a sticky tar-like substance that coats intake manifolds, intercoolers, and intake valves.
• Effects and Prevention: Black death reduces engine performance, increases fuel consumption, contributes to turbo failures by contaminating oil, and can cause rough running. Prevention includes regular oil changes with quality oil, using quality diesel fuel from reputable stations, allowing the engine to reach full operating temperature regularly rather than constant short trips, and preventative intake manifold cleaning every 50,000-80,000km. Some owners install catch cans to trap oil vapor before it enters the intake system. Professional intake cleaning costs £300-£600 depending on severity.

Timing Chain Problems (iLoad and i800):

• Warning Signs: Rattling noise from the front of the engine particularly on cold start, check engine light with timing-related codes, rough running, and loss of power. If low engine oil level is present alongside timing chain noise, this indicates potential chain slippage. Low oil pressure can also cause timing chain issues as the tensioner requires oil pressure to maintain proper chain tension.
• Immediate Action Required: Timing chain problems require immediate professional attention as continued driving can result in catastrophic engine failure. Chain failure causes valves to contact pistons resulting in bent valves, damaged pistons, and complete engine destruction requiring full rebuild or replacement costing £3,000-£5,000. Have the vehicle towed to a specialist rather than driving if timing chain failure is suspected. Timing chain replacement before failure costs £800-£1,500 depending on labor rates.

Staria-Specific Problems (2021-Present):

• Transmission and Transfer Case Issues: AWD Staria models experience rattles at certain speeds requiring transmission and transfer case replacement. Some owners report entire transmissions being replaced which actually made the problem worse, indicating technicians are unfamiliar with the new model. The Staria uses unique transmission, transfer case, and gear ratios not shared with Santa Fe despite marketing claims, making parts sourcing challenging and repairs expensive.
• Panoramic Window Breakage: The second-row panoramic windows in Staria people mover models are prone to breaking from the impact of closing rear sliding doors. This design flaw caused by large window area and special window structure has affected approximately 2,000 vehicles. Preventative measures include closing sliding doors gently and having window mechanisms inspected and adjusted by professionals.
• Electrical System Glitches: Collision avoidance systems occasionally stop working temporarily, powered boot malfunctions requiring manual closure multiple times before regaining control, and powered sliding doors randomly beep and jerk for unknown reasons possibly due to overly sensitive safety sensors. Most electrical issues are software-related and may be resolved by dealer software updates.
• Parts Availability Challenges: Staria-specific parts are unique to the model and extremely slow to arrive from Hyundai. Despite claims of platform sharing with Santa Fe, most mechanical components are Staria-specific and not interchangeable. This leads to extended repair times when parts are needed, particularly frustrating for commercial operators who need vehicles back on the road quickly.

Petrol Engine Issues (iLoad Petrol Variants):

• Theta Engine Failures: Petrol iLoad variants feature Theta family engines known for unexpected catastrophic failures. Failure causes include knock sensor calibration issues, oil pressure problems, manufacturing defects, and overall poor design. Unlike other regions where class action lawsuits resulted in free engine replacement programs, Australian iLoad petrol models are not included. When these engines fail, catalytic converter issues are common leading to power loss and potential long-term engine damage. Repairing Theta engines is often impractical due to the extent of internal damage, and second-hand replacements are scarce and expensive. Diesel variants do not suffer from this issue and are strongly recommended over petrol for reliability.

Hyundai Van Reliability Assessment:

Overall Good Reliability When Properly Maintained: Hyundai's reputation for commercial vans is built on the iLoad's decade-long track record (2007-2021) of solid build quality, robust reliability, good fuel economy, and driver comfort. The brand ranked third in the 2024-2025 J.D. Power Initial Quality Study demonstrating excellent manufacturing standards. Owner reviews consistently praise iLoad reliability with examples reaching 87,000 miles in hard taxi service requiring only front disc replacement, achieving 300,000km in commercial use, and delivering 31-35 mpg fuel economy. The Staria Load sold 3,503 units in 2024 making it second only to Toyota HiAce in commercial van sales.

Critical Maintenance Requirements: The key to Hyundai van reliability is strict adherence to 10,000km maximum service intervals rather than Hyundai's recommended 15,000km. Commercial vans get a hard life and cannot tolerate extended service intervals. Use high-quality fully synthetic diesel oil meeting Hyundai specifications. Address any turbo, injector, or coolant issues immediately before they cascade into expensive engine damage. When buying used iLoad or i800 models, verify full service history with evidence of 10,000km interval servicing, avoid petrol Theta engine variants, inspect for turbo and injector issues, and factor potential turbo replacement costs of £800-£1,800 into purchase price for higher-mileage examples.

Staria Considerations: The new Staria represents a significant departure from proven iLoad design with unique parts, complex electrical systems, and early teething issues including transmission rattles and window breakage. Parts availability is problematic with long wait times for Staria-specific components. Commercial operators should consider whether the Staria's advanced features justify these challenges compared to proven alternatives like Toyota HiAce. However, when operating correctly, the Staria offers excellent interior space, modern technology, and comfortable driving experience with proven 2.2-litre diesel engine shared with other Hyundai models.

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