Mitsubishi Van Parts UK - Quality Used & Genuine Parts

How to Replace Mitsubishi Headlights

Mitsubishi headlight replacement is straightforward across most commercial models. Whether replacing standard units on an L200 pickup or upgrading to better bulbs on a Shogun, this guide covers the main Mitsubishi van range.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Mitsubishi commercial vehicles provide good access to headlight assemblies. On the L200 and Shogun, the engine bay layout allows straightforward access. Locate the rear of the headlight unit from within the engine bay.
2. Disconnect the electrical connectors. Mitsubishi headlights have 2-4 electrical connectors depending on specification. These include main beam, dipped beam, side light, and indicator connectors. Press the release tabs carefully and pull straight out. Make note of connector positions.
3. Remove the headlight mounting bolts. Most Mitsubishi models use 10mm bolts to secure the headlight assembly. On the L200, there are typically 3-4 bolts along the top edge accessible once the bonnet is open. On Shogun and Outlander models, expect similar mounting arrangements. Remove all mounting bolts completely.
4. Release any retaining clips. Some Mitsubishi headlights have additional plastic clips for extra security. Check the inner corner and bottom edge for clips. Work carefully as clips can become brittle over time, especially on older L200 models.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward. Mitsubishi headlights slide forward on locating pins that ensure correct alignment. Support the weight as you pull to prevent dropping.
6. Transfer components if needed. If your replacement doesn't include bulbs, carefully transfer these from the old unit. Wear clean gloves when handling bulbs to avoid touching glass surfaces with bare hands as oils cause premature failure.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and pushing firmly into place ensuring all locating pins engage correctly. Refit all mounting bolts and tighten securely. Reconnect all electrical connections ensuring each clicks firmly. Test all lighting functions including main beam, dipped beam, side lights, and indicators before closing the bonnet.

Important Notes: Mitsubishi headlight replacement is simple on most commercial models. Never touch lens or reflector surfaces when handling new headlights. Check headlight alignment after fitting using adjustment screws on the rear of the assembly for optimal visibility and MOT compliance. The L200 and commercial derivatives have robust headlight mounting designed for off-road use.

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How to Replace Mitsubishi Front Bumper

Replacing a Mitsubishi front bumper takes 60-90 minutes depending on model. This process covers L200 pickups, Shogun SUVs, and Outlander models, though specific fixing locations vary between generations.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the upper bumper mounting bolts along the top edge. Mitsubishi models typically have 4-8 bolts securing the top of the bumper depending on model. On the L200, these are usually 10mm bolts. On Shogun and Outlander models, expect similar fixings. Remove all upper fixings systematically.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to maximize access to the wheel arch liner. Behind each front wheel, locate the plastic arch liner. Remove 3-5 plastic clips or screws securing the front section to expose side bumper mounting points. Mitsubishi uses plastic push-in clips that release by pressing the center pin first. Repeat on both sides.
3. Remove the side mounting bolts from both wheel arches. Behind each wheel arch liner, you'll find 2-4 bolts securing each side of the bumper. These are usually 10mm bolts on Mitsubishi models. Remove all side fixings on both driver and passenger sides. Keep track of fixings as they may differ between sides.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Locate and remove bolts and clips securing the engine undertray and lower edge of the bumper. Mitsubishi typically uses 8-12 fixings along the bottom edge. These may be 10mm bolts or plastic push-in clips. You don't always need to remove the entire undertray.
5. Disconnect fog lights 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, and any additional connections for cameras on newer Outlander and Shogun models. Press release tabs carefully and pull straight out. Count how many connections you disconnect.
6. Release the bumper clips and mounting tabs. Mitsubishi bumpers are secured by plastic clips 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.
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. L200 bumpers are reasonably robust due to commercial use. Shogun and Outlander bumpers are larger so benefit from a second person. Place the removed bumper on a protected surface.
8. Prepare and fit the replacement bumper. Before installation, transfer any brackets, trim pieces, tow bar mounts, or components from the old bumper if not fitted to your replacement. Align the new bumper with mounting points and push firmly ensuring all side clips engage. Reconnect all electrical connections including fog lights and parking sensors. Secure with all bolts and clips in reverse order. Test all electrical functions and check panel gaps are even on both sides before final tightening.

Top Tips: Mitsubishi bumpers are designed for practical replacement with commercial use in mind. When refitting parking sensors, ensure each clicks firmly into its mounting hole and sits flush. On L200 models with tow bars, check tow bar mounting points align correctly. Check all panel gaps between bumper and wings are even before final tightening. The L200's robust construction means replacement parts typically fit well.

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Common Mitsubishi Van Parts Problems & Solutions

Mitsubishi commercial vehicles have a formidable reputation for build quality and reliability. Japanese engineering means the number of reported problems compared to rivals is quite low. The L200 has over 4.7 million sales worldwide proving its durability. The Outlander scored an OVR reliability score of 81, placing it second in the top 10 most reliable SUVs. However, certain components can experience issues, particularly on higher-mileage examples or vehicles used for heavy commercial work. Here are the most commonly reported Mitsubishi van parts problems based on verified UK data.

Diesel Particulate Filter Issues (L200 2.5 Di-D):

• DPF Clogging: The most frequent complaint with the L200 concerns the diesel particulate filter, especially 2.5 Di-D engines with 136hp and 178hp. The particulate filter regularly becomes clogged leading to reduced engine performance, increased fuel consumption, and engine warning lights. These problems particularly affect vehicles used mainly for short journeys as the filter doesn't reach sufficiently high temperatures for self-cleaning. Typical symptoms include juddering engine at idle, black smoke from exhaust, and noticeable reduction in performance. First problems can occur as early as 40,000km with a second wave often appearing between 80,000-100,000km. Regular motorway driving at minimum 2000rpm for 20 minutes allows full regeneration. DPF replacement costs £1,500-£2,500. Some owners report going into limp mode just as joining motorways.

Manual Gearbox Problems (L200):

• Third Gear Issues: A common problem with the L200 is jumping out of third gear or difficult transition from second to third gear. This is a known fault that Mitsubishi repair under warranty involving stripping down the gearbox at approximately £1,000 cost. The problem particularly affects 2006-2015 models and can occur from as little as 25,000-35,000 miles. Symptoms include gear slippage when the transmission unexpectedly shifts out of gear due to worn synchronizers, hard shifting with difficulty changing gears caused by worn clutch or damaged shift cables, grinding noise during gear changes indicating worn synchronizers or damaged gear teeth, and clutch drag where the clutch fails to fully disengage. Many owners report this as frustrating especially when occurring just outside warranty periods. Mitsubishi are aware but often refuse goodwill gestures outside warranty.

Automatic Transmission Problems (L200):

• Shifting Issues and Limp Mode: The automatic transmission does not shift properly or doesn't engage all gears. Models from 2018 with 181hp particularly show these weaknesses from 50,000-70,000km mileage. Symptoms include flashing D warning light, engine management light, and vehicle going into limp mode. Low automatic transmission fluid is a common cause. Regular ATF checks and changes prevent issues. Automatic models sometimes feel like they're in too high a gear when doing 10-30mph and sound like slipping when changing gears. Transmission repairs can be expensive at £1,500-£3,000.

Leaf Spring Failures (L200):

• Cracked Leaf Springs: The L200 leaf springs are known to crack if the owner regularly carries heavy loads or tows heavy trailers. Usually signalled by a regular knocking sound coming from either of the rear wheels. This is common on commercial vehicles used at maximum payload capacity. Replacement leaf springs cost £200-£500 per side depending on specification. Upgraded heavy-duty leaf springs are available for vehicles regularly used for towing or heavy loads.

Head Gasket Leaks (L200):

• Head Gasket Failure: A less common but significant fault is head gasket leaking on the L200. This seal between cylinder heads and engine block can eventually leak particularly on higher-mileage examples around 80,000 miles. Listen for radiator bubbling and failing as this can be a sign of head gasket leaking. Problems with engine overheating can also affect the head gasket. Symptoms include white smoke from exhaust, coolant loss, overheating, and bubbling sounds after engine shutdown. Head gasket replacement costs £800-£1,500 depending on extent of damage.

Fuel System Problems:

• Fuel Filter Clogging: L200 fuel filters cause issues after roughly 30,000-40,000 miles with eventual clogging. Cheaper diesel types without lubricant or cleaner accelerate this problem. The high-pressure fuel pump can also fail resulting in starting problems, loss of power, and irregular engine running. Typical symptoms include engine difficult to start especially in cold temperatures, drop in power under load, or complete engine failure. Fuel injectors on older diesel models can clog faster than expected. Regular fuel filter changes every 30,000 miles prevent issues. Fuel pump replacement costs £400-£800.

Cooling System Failures:

• Water Pump and Thermostat Leaks: Water pump leaks often occur after 130,000-160,000km especially with irregular coolant changes. Thermostat leaks are also common. If the heating matrix is leaking, you'll notice antifreeze smell when driving or condensation on windows. The heating matrix is tricky to replace due to its location requiring significant time to access. Radiator damage can occur due to low ground clearance particularly on L200 models used off-road. Water pump replacement costs £200-£400. Check radiator supports and main coolant hose for damage if overheating quickly.

4WD System Malfunctions:

• All-Wheel Drive Problems: The all-wheel drive system shows frequent faults particularly in the electronic control system. Typical symptoms include illumination of the all-wheel drive warning light and limited traction. These problems occur more frequently after 80,000-120,000km. The traction control light is a common fault on the L200, commonly down to faulty sensors in the ABS system. Proper diagnostics are required to identify the exact cause. Transfer case issues can also develop on 4WD systems.

Suspension Wear (Outlander):

• Suspension System Problems: The most regular repair requests for the Outlander concern the suspension system. The UK's challenging road conditions including potholes and uneven surfaces exacerbate suspension problems. With over one million potholes in the UK, frequent bumps wear down suspension over time affecting performance and safety. Warning signs include unusual noises when driving over bumps, rougher than normal ride, or vehicle pulling to one side. Average repair requests for Outlander occur when the vehicle is 7.5 years old with around 81,291 miles. Average repair cost is £1,527.79 which is noticeably higher than many other SUVs. Addressing suspension issues promptly ensures smoother safer ride and maintains resale value.

Air Conditioning Failures:

• AC Compressor Defects: Common after 100,000-130,000km especially with intensive use in hot climates. AC system problems are reported across Mitsubishi models. In most cases, replacing the AC compressor or fan resolves issues without needing complete system replacement. Costs range from £300-£800 depending on component.

Timing Belt and Alternator Issues:

• Timing Belt Problems: Can occur as early as 90,000km although replacement interval is 100,000km. Follow manufacturer service schedules strictly. Alternator failure often occurs after 120,000-150,000km frequently due to wear of carbon brushes. Regular inspection prevents unexpected failures. Engine control unit defects can occur mainly in vehicles from 2006 and newer models after 100,000-150,000km resulting in loss of power and starting problems.

Rust and Corrosion (L200):

• Chassis and Body Rust: Even the mighty L200 can succumb to rust particularly around rear wheel arches and chassis. Some owners report more rust on chassis than paint despite 12-year rust warranty claims. Mitsubishi dealers sometimes classify it as natural corrosion rather than warranty-claimable rust. Side steps have been known to fall apart requiring replacement after long waits for parts. Regular washing and rust protection treatments help prevent corrosion. Check rear wheel arches and chassis thoroughly when buying used L200s.

Brake Disc Wear:

• Premature Brake Wear: Brake disc wear can be premature as early as 40,000-60,000km especially with frequent trailer use. The L200's heavy-duty use accelerates brake component wear. Regular brake inspections and quality replacement parts ensure safe operation. Front tyres can wear unevenly particularly on outside edge nearside and inside edge offside. Regular tracking checks minimize tyre wear.

Mitsubishi Van Reliability Assessment:

Generally Excellent Reliability: Japanese pickup trucks like the L200 have a formidable reputation for build quality. The number of L200 problems reported compared to rivals is quite low. Mitsubishi has over 50 years of car building experience with strong lineup of SUVs and rugged off-roaders. The L200 has accumulated over 4.7 million sales since 1978 proving its durability. The Outlander earns a respectable OVR score of 81, placing it second in the top 10 most reliable SUVs. Mitsubishi continues to honour the five-year/62,500-mile warranty provided with new cars even after leaving the UK market in 2021 due to poor sales. Used Mitsubishi vehicles remain popular among buyers due to proven reliability.

Maintenance is Critical: Most problems can be avoided through consistent maintenance and adapted driving style. Regular servicing prevents DPF, transmission, and cooling issues. For DPF health, ensure regular motorway driving at 2000rpm+ for 20 minutes. Change fuel filters every 30,000 miles. Inspect suspension components regularly especially if driving on poor roads or off-road. Address cooling system problems promptly. Check automatic transmission fluid levels regularly. Follow timing belt replacement intervals strictly. The L200 and other Mitsubishi commercials are fundamentally robust work vehicles but require regular attention to specific weak points. With proper care, Mitsubishi commercial vehicles deliver exceptional longevity and reliability justifying their reputation as ultimate hard-working vehicles.

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