Peugeot Van Parts UK - Quality Used & Genuine Parts

How to Replace Peugeot Van Headlights

Peugeot van headlight replacement is straightforward across most commercial models. Whether replacing standard units on a Partner or upgrading to LED on a Boxer, this guide covers the main Peugeot van range including 2024 facelift models with three-claw LED design.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Peugeot commercial vehicles provide good access to headlight assemblies. On the Partner, Expert, and Boxer, the engine bay layout allows straightforward access. Locate the rear of the headlight unit from within the engine bay.
2. Disconnect the electrical connectors. Peugeot headlights have 2-4 electrical connectors depending on specification. On 2024 facelift models with three-claw LED design, expect additional connectors for daytime running lights. These include main beam, dipped beam, side light, and DRL connectors. Press the release tabs carefully and pull straight out. Make note of connector positions.
3. Remove the headlight mounting bolts. Most Peugeot models use 10mm bolts or Torx screws to secure the headlight assembly. On the Partner and Expert, there are typically 3 bolts along the top edge accessible once the bonnet is open. On Boxer large vans, expect similar mounting arrangements with 3-4 fixings. Remove all mounting bolts completely and keep them organized.
4. Release any retaining clips. Some Peugeot 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 Boxer models that have been in service since 2006 platform.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward. Peugeot headlights slide forward on locating pins that ensure correct alignment. Support the weight as you pull to prevent dropping the unit especially on larger Boxer headlights.
6. Transfer components if needed. If your replacement doesn't include bulbs or LED modules, carefully transfer these from the old unit. On 2024 models with three-claw LED design, ensure LED modules are compatible. Wear clean gloves when handling bulbs to avoid touching glass surfaces with bare hands.
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 including DRL connectors on newer models. Test all lighting functions including main beam, dipped beam, side lights, and three-claw DRLs on 2024 models before closing the bonnet.

Important Notes: Peugeot headlight replacement is simple on most commercial models. The 2024 facelift introduced distinctive three-claw LED design requiring specific LED modules. 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.

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How to Replace Peugeot Van Front Bumper

Replacing a Peugeot van front bumper takes 45-75 minutes depending on model. This process covers Partner, Expert, and Boxer models including 2024 facelift versions with new bumper designs and closed-in grille.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the upper bumper mounting bolts along the top edge. Peugeot models typically have 4-6 bolts securing the top of the bumper depending on model. On the Partner and Expert, these are usually 10mm bolts or Torx screws. On Boxer large vans, expect 6-8 fixings across the top edge. The 2024 facelift models have new bumper designs requiring attention to closed-in grille mounting. 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 2-4 plastic clips or screws securing the front section to expose side bumper mounting points. Peugeot 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 2-3 bolts securing each side of the bumper. These are usually 10mm bolts on Peugeot models. Remove all side fixings on both driver and passenger sides. Keep track of fixings as they may differ between sides especially on Boxer with sectional unpainted grey plastic bumper design.
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. Peugeot typically uses 6-10 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 and parking sensor connections if equipped with rear parking sensors as standard on many models. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting.
6. Release the bumper clips and mounting tabs. Peugeot 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. On Boxer, the sectional bumper design means sections can be replaced individually.
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. Partner bumpers are lightweight and manageable. Expert bumpers are medium-sized. Boxer bumpers are larger so benefit from a second person. Place the removed bumper on a protected surface to avoid scratching the painted or unpainted sections.
8. Prepare and fit the replacement bumper. Before installation, transfer any brackets, trim pieces, or components from the old bumper if not fitted to your replacement. On 2024 facelift models, ensure new bumper design with closed-in grille is correctly oriented. 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: Peugeot bumpers are designed for practical replacement with sectional design on Boxer allowing individual section replacement reducing costs. When refitting parking sensors which come as standard on many models, ensure each clicks firmly into its mounting hole and sits flush. The Boxer's unpainted grey plastic front bumper sections are built to minimize repair costs. Check all panel gaps between bumper and wings are even before final tightening. The 2024 facelift introduced new bumper designs requiring specific parts.

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Common Peugeot Van Parts Problems & Solutions

Peugeot commercial vehicles benefit from legendary diesel engines renowned for reliability and fuel economy. The Partner, Expert, and Boxer diesel engines have become legendary for delivering exceptional performance even with heaviest loads on toughest journeys. The Boxer underwent over two million miles of testing in extreme conditions including half a million door openings at temperatures between -30°C and 80°C proving built to withstand harshest use. Peugeot offers three-year/100,000-mile warranty with service intervals every 30,000 miles or two years. However, certain components can experience issues particularly on higher-mileage examples or older Boxer models from 2006 platform. Here are the most commonly reported Peugeot van parts problems based on verified UK data.

Electrical Issues (Boxer):

• Electrical System Concerns: The Boxer's electrics can be a cause for concern though you'd be hard pushed to find competing large vans in affordable marketplace that don't have an achilles heel somewhere. Common electrical problems include wiring faults, sensor failures, and dashboard warning lights. The 2016 introduction of uprated 2.2-litre diesel to meet latest emissions legislation helped reliability but electrical gremlins persist on older models. Symptoms include intermittent faults, warning lights, and electrical component failures. Regular electrical system checks help identify issues early. Electrical repairs cost £200-£600 depending on component. The Stellantis platform sharing with Citroen Relay, Fiat Ducato, and Vauxhall Movano means extensive parts availability for electrical components.

Dated Platform Issues (Boxer):

• Aging Design: The Boxer has been around since 2006 with basics getting on for two decades old. Compared to modern rivals, there's little to be optimistic about. The van is noisy, uncomfortable, and has old-fashioned cabin. Ride quality is functional and not particularly refined with suspension handling larger bumps adequately but potholes and surface imperfections sending unpleasant jolts through cab. The Ford Transit, Mercedes Sprinter, and Renault Master all do much better job of isolating driver from road surface. Steering is light making urban maneuverability easy but can feel nervous and vague at higher speeds requiring frequent corrections during motorway driving. Despite dated feel, where Boxer scores well is where vans need to perform with huge payload area carrying heavy loads while providing impressive fuel economy up to 40.1mpg.

Engine Performance (Boxer Entry-Level):

• 120hp BlueHDi Struggles: The entry-level Boxer with 120hp BlueHDi diesel is only really suitable for lower-speed work. If you load it up the van will struggle with heavy payload though it will be rare occurrence to fully load van to maximum rated payload. The 2.2-litre BlueHDi diesel developed by Fiat is shared across Stellantis large van range with standard power output 138hp. The 140hp and 180hp versions provide better performance for varied customer needs. Torque stands at 258lb ft providing enough grunt for most hauling needs. Consider higher-powered engines for regular heavy loads or motorway work.

AdBlue System:

• AdBlue Tank and Sensors: The Boxer features emissions-reducing AdBlue tank with enormous 18.6-litre reservoir. Trip computer lets you know when refilling needed. AdBlue system problems can include sensor failures, crystallization, and tank issues. Regular AdBlue top-ups and using quality AdBlue prevent crystallization. AdBlue system repairs cost £200-£500. All modern diesel Peugeot vans use AdBlue meeting Euro 6d emissions standards.

Suspension Wear:

• Suspension Component Replacement: Suspension components wear over time especially on vans regularly carrying heavy loads or operating on poor road surfaces. The Boxer's suspension handles larger bumps adequately but can feel harsh on poor surfaces. Common replacements include shock absorbers, springs, and bushings. Suspension repairs cost £300-£700 depending on components. Regular inspection of suspension condition helps catch wear early preventing more expensive repairs.

Timing Chain (vs Timing Belt):

• Timing Chain Advantage: Unlike many vans, Peugeot engines use timing chain rather than belt so don't need to be replaced every 60,000 miles. This reduces maintenance costs significantly over ownership period. Timing chains typically last life of engine with proper maintenance. Change oil regularly to ensure timing chain longevity. This is major advantage of Peugeot diesel engines keeping long-term maintenance costs low.

Brake System:

• Brake Wear: Brake components wear normally with regular use. Front brake pads and discs typically need replacement every 30,000-50,000 miles depending on use. Rear brakes last longer. Brake system includes ABS with electronic brakeforce distribution and emergency brake assist as standard. Brake repairs cost £200-£500 for pads and discs. Regular brake inspections ensure safe operation.

Gearbox:

• Manual Transmission: All Peugeot diesel vans come with six-speed manual gearbox as standard with no automatic option on older models though 2025 Boxer introduced eight-speed automatic. The six-speed manual is smooth and reliable with light precise action. Clutch typically lasts 80,000-120,000 miles depending on driving style and use. The eight-speed automatic on newer Boxers provides smooth operation for urban stop-start driving and reduces driver fatigue on long journeys though with slight fuel consumption penalty. Gearbox repairs cost £800-£1,500 for major work though routine maintenance prevents most issues.

Fuel Economy:

• Legendary Diesel Efficiency: Peugeot diesel engines are legendary for fuel economy. The Partner and Expert achieve 34-38.7mpg. The Boxer officially manages up to 40.1mpg which while WLTP testing regime is generous isn't significantly behind that making van one of more economical models on market. With standard 90-litre fuel tank, Boxer provides range of 750 miles between fills at best economy. Fuel-saving stop-start comes as standard on modern models. Electric variants offer even lower operating costs with e-Partner up to 174 miles range, e-Expert 217 miles range, and e-Boxer 139 miles range.

Tyre Costs (Boxer Advantage):

• 15-Inch Tyres: The Boxer runs on 15-inch tyres which are economical to buy and easy to get hold of. This is significant advantage over rivals using larger more expensive tyres. Tyre replacement costs £80-£150 per tyre depending on brand and specification. Regular tyre rotation extends tyre life. The economical tyre size helps keep running costs down.

Maintenance Costs:

• Low Ownership Costs: Maintenance costs tend to be low on Peugeot vans. Service intervals are every two years or 30,000 miles meaning less expense on aftercare. Engines use timing chain rather than belt saving replacement costs. Peugeot offers service plans lasting 3-5 years for monthly fee. Parts sharing with Citroen Relay, Fiat Ducato, and Vauxhall Movano means extensive parts availability keeping costs competitive. The Stellantis family of large vans gives Boxer edge over competition in amount of shared parts available. Economies of scale make Peugeot vans good value against some models.

Peugeot Van Reliability Assessment:

Generally Excellent Reliability: Peugeot commercial vehicles offer excellent reliability with legendary diesel engines. The Partner, Expert, and Boxer have proven themselves as reliable workhorses for UK businesses. The Boxer should prove reliable choice for those buying used having undergone more than two million miles of testing in extreme conditions. Built to withstand harshest conditions with robust no-nonsense construction. Maintenance costs are low with service intervals up to 30,000 miles. Three-year/100,000-mile warranty provides excellent coverage with 12 months breakdown cover. Service plans available for 3-5 years.

Platform Sharing Advantage: The Boxer shares everything mechanically with Citroen Relay, Fiat Ducato, and Vauxhall Movano. This Stellantis family of large vans provides extensive parts availability and competitive pricing. The 2.2-litre BlueHDi diesel developed by Fiat is proven reliable across entire platform. Economies of scale mean good value and low running costs.

Regular Maintenance Critical: To maximize Peugeot van reliability, follow service schedules strictly. Change oil regularly to protect timing chain. Use quality AdBlue to prevent system issues. Inspect electrical systems regularly especially on older Boxer models. Address suspension wear promptly. Check brakes regularly. The legendary diesel engines deliver exceptional reliability and fuel economy when properly maintained. With service intervals every 30,000 miles and timing chains instead of belts, maintenance costs remain low. The 2024 facelift brought improvements to Partner and Expert with enhanced technology and cabin quality. Despite Boxer's dated platform from 2006, it remains reliable workhorse getting basics right with huge cargo space and impressive fuel economy.

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