KGM Car Parts UK - Quality Used & Genuine Parts

How to Replace KGM Headlights

KGM headlight replacement is straightforward on most models due to simple construction and accessible design. Whether replacing standard units on Tivoli and Korando or upgrading headlights on Torres and Rexton models, this guide covers the main KGM range including legacy SsangYong 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 Tivoli and Korando compact models, the engine bay provides adequate clearance for accessing headlight mountings despite relatively tight packaging. On Torres and Rexton larger SUVs, the higher bonnet line and more spacious engine bay make access easier. Musso pickup models offer excellent access due to commercial vehicle design with ample space. KGM engineering prioritizes serviceability meaning components are logically placed and accessible for basic maintenance without specialized tools.
2. Disconnect all electrical connectors. KGM headlights typically have 2-4 electrical connectors depending on specification and model year. These include main beam, dipped beam, side light, and on newer models like Torres additional connectors for LED daytime running lights. Press the release tabs carefully and pull straight out. KGM connectors use straightforward designs without complex locking mechanisms making disconnection simple. Take photos of connector positions before disconnecting to ensure correct reconnection during installation. On SsangYong legacy models, connector designs may vary between generations but follow similar principles. Handle all connectors by the plastic housing rather than pulling on wires to prevent damage.
3. Remove the headlight mounting bolts. Most KGM models use 10mm bolts or Phillips screws to secure the headlight assembly, though newer Torres models may use Torx screws. On Tivoli and Korando, there are typically 3-4 bolts along the top and side edges accessible once the bonnet is open. On Rexton and Torres larger models, expect 4-5 mounting bolts with clear access from above. Musso pickup models follow commercial vehicle conventions with robust mounting using 3-4 bolts. Remove all mounting bolts completely and keep them organized. KGM uses straightforward mounting without hidden fixings common on premium brands, simplifying the replacement process significantly.
4. Release any additional clips or retainers. Some KGM headlights use supplementary plastic clips at various points for additional security beyond main mounting bolts. On older SsangYong models, check for clips at the inner corner near the grille. On newer KGM models like Torres, the updated design may have clips at the bottom edge. KGM clips are generally robust but can become brittle with age on older SsangYong models. Work carefully using a trim removal tool rather than forcing clips as replacements may require ordering from dealers. The simple construction means fewer clips overall compared to premium brands.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. KGM headlights slide forward on simple locating pins that ensure correct alignment during installation. Support the weight as you pull to prevent dropping though KGM headlights are generally lighter than premium equivalents due to straightforward construction without complex adaptive systems. If you feel resistance, stop and check for missed fixings rather than forcing. The simple design means removal should be straightforward once all fixings are released.
6. Transfer components to new headlight if needed. If your replacement doesn't include bulbs or any additional components, 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 failure. Most KGM models use conventional halogen bulbs that are inexpensive and readily available, though newer Torres models may feature LED technology. Check bulb specifications match between old and new headlights before installation. KGM's use of standard components means replacement bulbs are affordable compared to premium brands with proprietary LED units.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and locating tabs. Push firmly into place ensuring all locating pins engage correctly. KGM's simple design means headlights fit precisely without complicated adjustment when mounted correctly. Refit all mounting bolts and tighten securely avoiding overtightening which can crack mounting tabs. Reconnect all electrical connections ensuring each clicks firmly. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and indicators to confirm proper operation. Check headlight alignment after fitting using adjustment screws on the rear of the assembly as proper alignment is crucial for MOT compliance and safety.

Important Notes: KGM headlight replacement is generally straightforward thanks to simple construction and accessible design. The brand's focus on practical, serviceable vehicles means DIY maintenance is more achievable than premium competitors. When handling new headlights, never touch lens or reflector surfaces as contamination affects light output. KGM headlights are reasonably priced compared to premium brands making replacement more affordable. For SsangYong legacy models, headlights remain available through KGM dealers and specialist breakers. Check headlight alignment after fitting as proper alignment is crucial for optimal visibility and MOT compliance.

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How to Replace KGM Front Bumper

Replacing a KGM front bumper is achievable in 45-75 minutes depending on model. This process covers Torres, Korando, Tivoli, Rexton, and Musso models including legacy SsangYong vehicles, though specific screw locations vary between generations. KGM's straightforward construction makes bumper replacement more accessible than premium brands.

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 KGM models have 4-8 fixings across the top depending on model size. On Tivoli and Korando compact SUVs, expect 4-6 fixings across the top using 10mm bolts or Phillips screws. On Torres and Rexton larger SUVs, typically 6-8 fixings secure the top edge. Musso pickup models follow commercial vehicle conventions with robust mounting. Remove all upper fixings systematically working from one side to the other. KGM uses simple mounting without complex hidden fixings common on premium brands.
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 to expose side bumper mounting points. KGM typically uses push-in clips that release by pressing the center pin first, or Phillips screws on some models. The quality of KGM clips is generally adequate though older SsangYong models may have clips that have become brittle with age. Repeat on both sides for symmetry. The simple construction means arch liner removal is straightforward.
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. These are usually 10mm bolts or Phillips screws on KGM models. Remove all side fixings on both driver and passenger sides. Keep track of which fixings came from which location as they may differ in length between top and side positions. KGM engineering means fixings are logically placed and easily visible once arch liners are moved aside, simplifying the process compared to premium brands with complex mounting systems.
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. KGM typically uses 6-10 fixings along the bottom edge depending on model. These may be 10mm bolts, Phillips screws, or push-in clips. On Rexton and Torres larger SUVs, the undertray may be more substantial. Musso pickup models have minimal undertray due to commercial vehicle design. You don't always need to remove the entire undertray but may need to lower it for access to bumper fixings.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors including fog lights if fitted (standard on higher trim levels), parking sensor connections if equipped (common on Torres and Rexton top specifications), and any additional connections for cameras on newer models. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting. KGM uses straightforward connectors without complex locking mechanisms making disconnection simple. Older SsangYong models may have fewer electrical connections due to simpler specifications.
6. Release the bumper side clips and mounting tabs. KGM bumpers are secured by plastic clips or simple 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. KGM's simple mounting means bumpers release relatively easily compared to premium brands with complex multi-point mounting systems. Work carefully as older SsangYong bumpers may have clips that have become brittle, though damage is less costly to repair than premium equivalents.
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. KGM bumpers are reasonably lightweight due to simple construction without complex reinforcement. Tivoli and Korando compact SUV bumpers are easily handled by one person. Torres, Rexton, and Musso larger vehicle bumpers benefit from a second person due to size. Place the removed bumper on a protected surface to avoid scratching the painted surface. KGM bumpers are less complex than premium brands making replacement more straightforward.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, fog lights, or sensors from the old bumper if not fitted to your replacement. Check the condition of all mounting clips and replace if damaged as KGM replacement clips are reasonably affordable. 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 and parking sensors ensuring each clicks firmly. Systematically secure with all screws and clips in reverse order. Test all electrical functions before final assembly including fog lights and parking sensors. Check panel gaps are even on both sides for professional appearance. KGM's simple construction means fitment is straightforward when done correctly.

Top Tips: KGM bumpers are engineered for practical serviceability making DIY replacement achievable for competent home mechanics. When refitting parking sensors on equipped models, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. Check all panel gaps between bumper and wings are even before final tightening. KGM bumpers are significantly cheaper than premium brand equivalents making replacement more affordable. For SsangYong legacy models, bumpers remain available through KGM dealers, specialist breakers, and the used market. The straightforward construction means fitment issues are rare when all fixings are correctly installed.

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Common KGM Parts Problems & Solutions

KGM Motors (formerly SsangYong) vehicles are known for being tough, durable, and hard-working with a reputation for solid reliability. The brand offers a generous 5-year warranty covering 100,000 miles matching Hyundai, demonstrating confidence in durability. With 70 years of manufacturing heritage, KGM builds simple practical vehicles without excessive complexity. However, certain issues are commonly reported. Here are the most frequently encountered KGM parts problems based on verified data from UK owners, mechanics, and industry sources.

Poor Fuel Economy and Thirsty Engines (Torres, Tivoli):

• Disappointing Real-World Consumption: The 1.5L turbocharged petrol engine used in Torres and Tivoli models suffers from poor fuel economy despite official figures suggesting 33 mpg for Torres. Real-world town driving typically returns less than 30 mpg making these engines incredibly thirsty for their size and segment. Owners report fuel returns well below expectations particularly in urban environments where the turbo engine works hard. The Torres priced £33,000-£38,000 competes with efficient rivals like Nissan Qashqai and Hyundai Tucson that deliver significantly better fuel economy. The Tivoli despite lower pricing also disappoints at the fuel pumps with consumption below 30 mpg common during town driving described as dreadful by reviewers.
• Engine Refinement Issues: Beyond poor economy, the 1.5L turbo engine is criticized as noisy and unrefined compared to competitors. The engine lacks the smoothness and quietness expected in modern family SUVs making it tiresome on longer journeys. While power output appears decent on paper (163 hp in Torres), the delivery is accompanied by excessive noise that intrudes into the cabin. The price paid for adequate performance is poor refinement and terrible fuel consumption. KGM is addressing concerns with a hybrid variant coming in 2025 which should significantly improve both economy and refinement. Until then, prospective buyers must accept poor fuel economy as a trade-off for lower purchase prices and generous equipment levels.

Basic Interior Quality and Materials:

• Uninspiring Cabin Finish: KGM vehicles suffer from basic interior quality that falls behind mainstream competitors. The Tivoli dashboard is particularly criticized as feeling cheap and basic despite generous equipment levels. Materials used throughout KGM interiors are functional rather than premium with hard plastics dominating rather than soft-touch surfaces. Fit and finish is adequate but lacks the precision and quality feel of rivals from Hyundai, Kia, or even budget champion Dacia in its latest forms. The simple construction that makes KGM vehicles reliable also means interiors feel dated and uninspiring compared to modern competitors.
• Value Proposition Trade-Off: The basic interiors must be viewed in context of KGM's competitive pricing and generous equipment specifications. Despite cheaper materials, KGM vehicles typically include substantial standard equipment that competitors charge extra for. The trade-off is between premium materials and value for money. Buyers accepting basic interiors benefit from lower purchase prices, generous warranties, and high equipment levels. Those prioritizing premium feel should look elsewhere. The smaller family-owned KGM dealers often provide more pleasant service experiences than large corporate dealerships partially offsetting interior quality concerns.

Limited Driving Dynamics and Refinement:

• Not Enjoyable to Drive: KGM vehicles prioritize practicality over driving engagement resulting in uninspiring dynamics. The Tivoli is described as not very enjoyable to drive with handling and steering lacking the precision and feedback of rivals. While adequate for basic transportation, KGM models don't deliver the driving satisfaction that competitors from mainstream brands provide. The focus on simple, robust construction means suspension tuning prioritizes durability over sportiness. For buyers seeking driving enjoyment, KGM vehicles disappoint. However, for those prioritizing low purchase price, generous equipment, and practical space over dynamic excellence, KGM delivers adequate competence.

Safety Ratings and Crash Test Performance:

• Outdated Crash Test Results: The Tivoli was last tested by Euro NCAP in 2016 when it was a SsangYong, scoring only four stars even under less rigorous historical testing standards. Under today's significantly more demanding tests, it likely wouldn't achieve four stars demonstrating safety equipment and structural performance lags behind modern competitors. Newer models like Torres haven't been tested yet making safety performance unknown. Standard equipment includes reasonable safety features such as seven airbags, autonomous emergency braking, and lane-keeping aids across the range. Higher K40 trim levels add extras such as traffic sign recognition and blind-spot monitoring. However, the lack of recent five-star Euro NCAP ratings means safety-conscious buyers should consider more recently tested competitors.

Limited Reliability Data Due to Low Sales Volumes:

• Insufficient Statistical Evidence: The brand simply doesn't sell enough cars in the UK for meaningful reliability data to exist. Without significant sales volumes, statistical analysis of common faults and long-term durability is impossible. Reviewers acknowledge this limitation stating they cannot provide definitive reliability verdicts. For what it's worth, KGM vehicles are fairly simple without too much complexity to go wrong. The straightforward mechanical construction and lack of advanced technology should theoretically improve reliability by reducing potential failure points. The generous 5-year/100,000-mile warranty provides peace of mind compensating for lack of statistical evidence.
• SsangYong Historical Reputation: Under the previous SsangYong name, vehicles were described as fairly solid and reliable if not particularly sophisticated. The brand built a reputation for tough durable vehicles capable of withstanding hard use. Earlier models used older Mercedes diesel engines in larger vehicles like Rexton providing proven reliability. Newer models use KGM's own engines without the track record of Mercedes units. The 70-year manufacturing heritage suggests competent engineering though modern reliability standards have increased significantly. Legacy SsangYong owners generally report adequate reliability with issues typically minor rather than catastrophic.

Limited Dealer Network and Parts Availability:

• Small Dealer Network: KGM operates 73 UK dealerships compared to hundreds for mainstream brands like Ford, Vauxhall, or Volkswagen. The limited network means some owners face longer distances to reach authorized service centers. However, KGM dealers tend to be smaller family-owned businesses rather than huge corporate dealerships providing more pleasant personal service experiences. Parts availability for newer KGM models should be adequate through the dealer network. For older SsangYong legacy models, some parts may require ordering from Korea causing delays. The specialist nature of the brand means independent mechanics may lack familiarity with KGM vehicles though the simple construction makes them easier to work on than complex premium brands.

Rexton and Musso Specific Considerations:

• Older Platform and Design: The Rexton and Musso continue using older platforms and designs from the SsangYong era. While this ensures proven durability and off-road capability with ladder-frame chassis construction, it also means these models feel dated compared to modern monocoque SUVs and pickups. The Musso as KGM's best-selling UK model demonstrates appeal among buyers prioritizing practicality and value over sophistication. Strong towing capacity and one-tonne payload make it genuine working vehicle. The Rexton seven-seat capability with spacious third row appeals to large families. Both models offer exceptional warranty coverage rare in commercial vehicle and seven-seat segments. However, buyers should expect basic refinement and older technology compared to mainstream competitors.

KGM Reliability Assessment:

Adequate Reliability with Value Proposition: KGM vehicles represent a value proposition trading sophistication and premium features for lower purchase prices and generous equipment. The brand's reputation for tough durable vehicles suggests adequate reliability despite lack of statistical evidence from limited UK sales volumes. The generous 5-year/100,000-mile warranty matching Hyundai provides excellent protection and demonstrates manufacturer confidence. Simple construction without excessive complexity should theoretically improve long-term reliability by reducing potential failure points. However, poor fuel economy, basic interiors, limited driving dynamics, and outdated safety ratings mean KGM vehicles aren't for everyone. The brand suits buyers prioritizing low purchase price and generous warranties over premium refinement and efficiency. Family-owned dealers provide pleasant service experiences. The 2024 rebrand represents fresh start with newer models like Torres showing design improvements, though mechanical sophistication remains behind mainstream competitors.

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