MAN Van Parts UK - Quality Used & Genuine Parts

How to Replace MAN TGE Headlights

MAN TGE headlight replacement is straightforward and follows the same process as VW Crafter since they share identical components. Whether replacing standard halogen units or upgrading to LED headlights, this guide covers all TGE panel van, chassis cab, and crew cab variants.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely with the prop rod. The MAN TGE has excellent bonnet access typical of large commercial vans. Locate the rear of the headlight assembly from within the engine bay. The headlight mounting area is easily accessible from above with clear visibility of all fixings.
2. Disconnect all electrical connectors from the headlight. MAN TGE headlights typically have 2-3 electrical connectors depending on specification including main beam, dipped beam, and side light connections. Press the release tabs on each connector carefully and pull straight out. On models with LED headlights there may be additional connectors for daytime running lights. Handle all connectors gently to avoid damaging the locking tabs.
3. Remove the headlight mounting bolts. The TGE uses T20 or T25 Torx screws to secure the headlight assembly, typically 2-3 bolts along the top edge accessible once the bonnet is open. These bolts are clearly visible and easy to access. Remove all mounting bolts completely and keep them organized for refitting. The bolt locations are identical to VW Crafter so replacement parts interchange perfectly.
4. Release any additional clips or retainers. Some MAN TGE headlights use supplementary plastic clips at various points around the headlight perimeter for additional security. Check for clips at the inner corner near the grille and along the bottom edge. Work carefully as clips can become brittle with age on older vans. If clips break during removal, replacement clips are inexpensive and available from breakers.
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. MAN TGE headlights slide forward on locating pins that ensure correct alignment. Support the weight of the headlight as you pull to prevent dropping. If you feel resistance, stop and check for missed fixings rather than forcing which could damage mounting points.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs or other components, carefully transfer these from the old unit. When handling halogen or LED bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as skin oils cause premature bulb failure. Check that all seals and gaskets are in good condition when transferring 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 in their mounting holes. Refit all mounting bolts and tighten securely but avoid overtightening which can crack plastic mounting points. 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. Check headlight alignment after fitting and adjust if necessary using adjustment screws on the rear of the assembly.

Important Notes: MAN TGE headlight replacement is identical to VW Crafter procedure. When handling new headlights, never touch lens or reflector surfaces. LED headlights may require coding to the ECU on some models to avoid warning lights, though this is rare on TGE vans. Proper headlight alignment is crucial for optimal visibility and MOT compliance. The MAN dealer network can perform headlight alignment checks if needed, though most replacements don't require adjustment if mounting pins are properly engaged.

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How to Replace MAN TGE Front Bumper

Replacing a MAN TGE front bumper is achievable in 60-90 minutes depending on specification. This process is identical to VW Crafter as they share all body panels. The procedure covers panel van, chassis cab, and crew cab variants.

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. The MAN TGE typically has 4-6 Torx screws or bolts securing the top edge of the bumper. These are usually T20 or T25 Torx screws clearly visible once the bonnet is open. Remove all upper fixings systematically and keep them organized as you'll need them for refitting.
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 which provides access to side bumper mounting points. Remove or release 2-4 plastic clips or screws securing the front section of the arch liner to expose the side bumper fixings. MAN uses plastic push-in clips that release by pressing the center pin first then pulling the outer clip. Repeat the process on both driver and passenger sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner you'll find 2-4 screws or bolts securing each side of the bumper to the wing and chassis. These are usually T20 or T25 Torx screws on MAN TGE vans. Remove all side fixings on both sides and keep track of which fixings came from which location as they may differ between driver and passenger sides.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands never work under a vehicle supported only by a jack. Locate and remove all screws and clips securing the engine undertray and lower edge of the bumper. The MAN TGE typically uses 6-10 fixings along the bottom edge. These may be Torx screws or plastic push-in clips. You don't always need to remove the entire undertray, just the front section that overlaps with the bumper.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors. This includes fog light connections if fitted, parking sensor connections if equipped with parking assist (MAN TGE often has front parking sensors as standard or optional equipment), and any additional connections for cameras or radar on models with driver assistance systems. Press release tabs carefully and pull straight out without forcing. Count how many connections you disconnect to ensure you reconnect them all during refitting.
6. Release the bumper side clips and mounting tabs. MAN TGE 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 from side to side to release the clips. Listen for clicks as clips disengage. The bumper should come free relatively easily once all fixings are removed.
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. MAN TGE bumpers are reasonably large and benefit from a second person to help support and maneuver the bumper clear of the vehicle. Place the removed bumper on a protected surface or hang it safely to avoid scratching the painted surface or damaging any components attached to it.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, fog lights, parking sensors, or other components from the old bumper if not already fitted to your replacement. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly into the wing mounting points. Reconnect all electrical connections including fog lights and parking sensors ensuring each connector clicks firmly. Systematically secure the bumper with all screws and clips in reverse order of removal, starting with side fixings, then top fixings, then undertray fixings. Test all electrical functions before final assembly including fog lights and parking sensors. Check panel gaps are even on both sides and adjust if necessary before final tightening.

Top Tips: MAN TGE bumpers are identical to VW Crafter bumpers so replacement parts interchange perfectly. When refitting parking sensors, ensure each sensor clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. Some MAN TGE models have front-mounted radar for adaptive cruise control or collision warning systems which may require recalibration at a MAN or VW dealer after bumper replacement. Check all panel gaps between bumper and wings are even before final tightening of all fixings. The shared platform with VW Crafter means parts availability is excellent and replacement bumpers typically fit well without extensive adjustment.

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Common MAN Van Parts Problems & Solutions

MAN vehicles are renowned for commercial vehicle expertise and robust engineering. The TGE van shares VW Crafter's excellent reliability, while MAN's truck range including TGL, TGM, TGS, and TGX are described by operators as bulletproof. What Car? awarded the MAN TGE 5 out of 5 stars in 2025, praising it as one of the very best buys in the large van class. However, certain components can experience specific issues. Here are the most commonly reported MAN parts problems based on verified data from UK operators, mechanics, and industry specialists.

MAN TGE Van Reliability (Excellent - Identical to VW Crafter):

• Overall Assessment: The MAN TGE is essentially a rebadged VW Crafter built in the same Polish factory to identical specifications. This means TGE reliability mirrors Crafter reliability which is excellent in the large van class. What Car? awarded the TGE 5 out of 5 stars in 2025, describing it as one of the very best buys in large van class with praise for comfort, driving dynamics, ease of customization, and value. Honest John awarded the TGE Large Van of the Year in 2019. The TGE comes with a 3-year/100,000-mile warranty and servicing intervals every 24 months or 30,000 miles.
• Unique MAN Advantages Over VW Crafter: While mechanically identical to the Crafter, the TGE offers significant operational advantages through MAN's commercial vehicle heritage. MAN operates 24-hour service centers as part of their truck network, allowing TGE owners to book servicing and repairs out of hours which is invaluable for busy businesses minimizing downtime. This 24/7 Mobile24 breakdown and maintenance service is the same support MAN truck owners receive, meaning your van should be off the road for the shortest time possible when maintenance is needed. This extended service capability genuinely differentiates the TGE from segment rivals including its VW Crafter sibling. Additionally, MAN TGE prices are typically 5% lower than equivalent VW Crafter specifications due to agreed pricing structures within the VW Group.
• TGE Specifications: The TGE range uses VW's proven 2.0L TDI turbodiesel in four power outputs of 102hp, 122hp, 140hp, and 177hp (the 102hp variant was discontinued in 2025 due to low demand). Torque ranges between 300Nm and 410Nm. Fuel economy averages 27-33 mpg on the combined cycle depending on engine, load, and driving conditions. Front-wheel drive is standard with rear-wheel drive and all-wheel drive options available. Six-speed manual gearbox is standard with excellent eight-speed automatic transmission available as optional extra. Gross vehicle weights range from 3.0 tonnes to 5.5 tonnes, with 3.5 tonnes being the highest you can drive on a regular car license. Maximum cargo capacity reaches 18,400 litres in extra-long super-high roof variants with payload up to 1,400kg depending on specification.
• Common TGE Issues (Mirrors Crafter Problems): Since the TGE shares all components with the VW Crafter, it experiences the same minor issues. These include occasional DPF regeneration issues on vans used primarily for short urban journeys where the DPF doesn't reach temperature for proper regeneration, AdBlue system faults on Euro 6 models though these are relatively rare, and minor electrical glitches on higher-mileage examples. Regular servicing and using quality diesel fuel minimizes DPF issues. Overall reliability is excellent with most TGE vans providing trouble-free service for many years and high mileages.

MAN eTGE Electric Van (Limited Range But Reliable):

• Electric Powertrain: The eTGE launched in 2018 as MAN's first electric commercial vehicle. It features a 134hp (100kW) electric motor and 36kWh battery providing WLTP range up to 71 miles. While this limited range makes the eTGE unsuitable for long-haul work, it proves excellent for urban last-mile delivery, city-based operations, and short-distance commercial applications. The eTGE charges in 5.5 hours from a MAN AC wallbox or 45 minutes to 80% from a 40kW rapid charger. Importantly, the eTGE makes no compromises on cargo space versus diesel TGE models, offering the same load volumes and practical commercial features.
• Running Costs and Reliability: The eTGE offers significantly lower running costs than diesel for urban operations with no fuel costs, minimal servicing requirements (no oil changes, DPF, AdBlue, or exhaust system maintenance), and free entry to congestion charging zones and ULEZ areas in London and other UK cities. The electric powertrain is proven reliable with fewer moving parts than diesel engines. Battery degradation is minimal on well-maintained examples. The main limitation remains the 71-mile range which requires careful route planning and access to charging infrastructure.

MAN Euro-5 Truck EGR Problems (TGS, TGX - Mostly Resolved):

• Euro-5 Engine Issues: Early MAN TGS and TGX trucks equipped with Euro-5 emissions standards and EGR (Exhaust Gas Recirculation) systems experienced well-publicized problems with EGR valves and high-pressure intercoolers on D20 and D26 engines. These issues affected trucks manufactured approximately 2007-2012 before Euro-6 emissions standards. Problems included EGR valve failures causing loss of power and excessive smoke, intercooler failures leading to coolant leaks and engine damage, and carbon buildup in intake systems reducing performance.
• Current Status: Euro-5 MAN trucks are now becoming rare in the UK market as most have been replaced by newer Euro-6 vehicles. Most Euro-5 trucks still in operation have had EGR and intercooler issues resolved through dealer updates and component replacements. If buying a used MAN truck from the Euro-5 era, verify that any EGR-related recalls or updates have been completed and check service history for evidence of EGR or intercooler work. Euro-6 TGS and TGX trucks introduced from 2012 onwards have proven highly reliable with operators consistently describing them as bulletproof.

MAN Euro-6 Truck Reliability (TGL, TGM, TGS, TGX - Excellent):

• Operator Feedback: Euro-6 MAN trucks from 2012 onwards are consistently praised for excellent reliability. Commercial Motor magazine reported that operator after operator described the Euro-6 TGX as bulletproof with very few issues even on high-mileage examples. The same reliability applies to TGL, TGM, and TGS models. As is typical with modern commercial vehicles, there genuinely isn't much that goes wrong with them when properly maintained. Issues that do occur are generally minor and easily resolved.
• Minor Euro-6 Truck Issues: The few niggles reported on MAN Euro-6 trucks include wing mirror backs being vulnerable to shattering or dropping off with minor impacts (keep spare mirror backs in stock), door hinges bending easily causing doors to drop particularly when driver's door is opened in windy conditions and allowed to bang against stoppers, fuel filter tap mounted externally being prone to being knocked by forklift trucks during loading at trailer headboard (easily guarded), radar boxes mounted on front being knocked off during automatic washing (check mounting is firm), and rear air tanks fouling on trailer legs on some examples if fifth wheel position isn't checked before reversing under trailers with deep pins. These are all minor issues easily prevented or repaired.

MAN TGX High-Mileage Issues (800,000km+):

• Clutch and Seal Problems: On very high-mileage TGX trucks over 800,000km, operators report occasional clutch disc failures where the driven clutch disc breaks and springs get loose. This is normal wear on trucks with such extreme mileage. Coolant sensor leaks have also been reported where coolant leaks from sensors, resolved by draining antifreeze, degreasing the sensor well, applying reliable sealant, and reinserting the sensor. Air conditioning malfunctions are occasionally reported on older high-mileage trucks which is uncomfortable in hot weather but doesn't affect vehicle operation. These issues are minor considering the extreme mileages MAN trucks regularly achieve.

MAN TGS and TGM Specifications:

• TGS Heavy-Duty Range: The TGS launched in 2007 as The Assertive One is available in 2-axle, 3-axle, and 4-axle configurations for semitrailer, chassis, and tipper applications. Features include body-friendly frame design, lightweight construction for maximum payload, revised bumper with heating protection, variable axle load ratio for optimal traction, and spacious M/L/LX cabs with HD LCD display and digital networking. Standard equipment includes sustained action braking system EVB, tyre pressure monitoring TPM, digital axle load system, auto-gearshift system, and MAN HydroDrive selectable front-axle drive for greater traction when required. The TGS WW variant is configured for challenging applications in harsh mining environments.
• TGM All-Rounder Range: The TGM launched in 2005 as The All-rounder covers 15-26 tonne GVW range in 4x2, 4x4, 6x2, and 6x4 axle configurations. Powered by 6.9L D0836 six-cylinder diesel engines rated at 250hp, 290hp, and 320hp consuming 5% less fuel compared to predecessors while meeting Euro-6 compliance. Features weight-optimised front axle increasing payload, aerodynamic cab design with C/L/LX/crew cab options, electronic braking system EBS, anti-slip control ACS, and electronic stability programme ESP. The TGM bridges the gap between light distribution vans and heavy construction trucks.

Prevention and Maintenance:

Maximizing MAN Reliability: To ensure maximum reliability from MAN vehicles, adhere strictly to MAN service schedules without extending intervals. For TGE vans, follow the 24-month or 30,000-mile service intervals. Take advantage of MAN's 24/7 service network for out-of-hours maintenance to minimize business downtime. Use only quality diesel fuel and genuine or OE-quality parts. For trucks, regular oil changes using correct specification oil are critical. Address any DPF warning lights immediately on Euro-6 vehicles. Monitor AdBlue levels and top up with quality AdBlue fluid. When buying used MAN vehicles, prioritize Euro-6 models from 2012 onwards to avoid Euro-5 EGR issues, verify full service history preferably from MAN dealers, and have pre-purchase inspections performed by MAN specialists or authorized workshops. MAN vehicles offer excellent reliability when properly maintained, with the TGE van matching VW Crafter's proven dependability and MAN trucks delivering bulletproof performance in commercial operations.

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