Toyota Van Parts UK - Quality Used & Genuine Parts

How to Replace Toyota Headlights

Toyota headlight replacement is straightforward on most commercial models thanks to practical, user-friendly engineering. Whether replacing damaged units on your Hilux pickup or upgrading headlights on a Proace van, this guide covers the complete process for all Toyota 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 Hilux pickups, the body-on-frame construction and spacious engine bay provide excellent access to headlight mountings. On Land Cruiser models, expect similarly generous access despite the larger vehicle. On Proace and HiAce vans, the semi-forward control layout means headlight access is straightforward from above once the bonnet is open. Toyota's practical engineering philosophy ensures maintenance accessibility.
2. Disconnect all electrical connectors from the headlight. Toyota headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. On higher-specification models with LED daytime running lights or adaptive headlights, there may be additional connectors. Press the release tabs carefully and pull straight out. Toyota electrical connectors are typically robust and well-designed, reflecting the brand's reputation for quality engineering, but handle carefully as replacement parts maintain excellent availability through Toyota's strong UK dealer network.
3. Remove the headlight mounting bolts. Most Toyota models use 10mm or 12mm bolts to secure the headlight assembly. On Hilux and Land Cruiser models, there are typically 3-4 mounting bolts along the top and side edges, easily accessible once the bonnet is open. On Proace vans, expect similar straightforward bolt arrangements. The practical design reflects Toyota's focus on serviceability and ease of maintenance. Remove all mounting bolts completely and keep them organized for reassembly.
4. Release any additional clips or retainers. Some Toyota headlights use supplementary plastic clips for additional security. On Hilux pickups, check for clips at the inner corner near the grille. On Proace vans, look for clips securing the headlight to the surrounding bodywork. Work carefully as clips can become brittle with age, though Toyota's quality materials mean they typically remain serviceable longer than competitors. The robust construction reflects Toyota's durability focus.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. Toyota headlights vary in size depending on model, with Hilux and Land Cruiser units being substantial while Proace headlights are more compact. Support the unit as you pull to prevent dropping. If you feel resistance, stop and check for missed fixings rather than forcing. Toyota's quality control means mounting points are typically precise and well-aligned.
6. Transfer components to new headlight if needed. If your replacement doesn't include bulbs or adjustment mechanisms, 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. This is particularly important on commercial vehicles that operate long hours in demanding conditions. On models with integrated LED headlights, the entire unit is typically replaced as a complete assembly rather than individual bulbs.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting points and push firmly into place ensuring all locating features engage correctly. Refit all mounting bolts and tighten securely following proper torque specifications. Reconnect all electrical connections ensuring each clicks firmly. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and any additional functions like daytime running lights. Check headlight alignment using adjustment screws on the rear of the assembly. Proper alignment is crucial for optimal visibility and MOT compliance, particularly important on commercial vehicles operating at night or in challenging conditions.

Important Notes: Toyota headlight replacement is achievable in 30-45 minutes on most models thanks to the brand's focus on practical, maintainable design. Parts availability is excellent through Toyota's strong UK dealer network, ensuring you can source correct replacement units quickly without the wait times affecting some manufacturers. When buying replacement headlights, verify they match your vehicle's specification as Toyota made updates throughout production runs. On Hilux and Land Cruiser models used for off-road work, inspect mounting points for damage from impacts and address any issues before fitting new headlights. Proper headlight alignment is essential for safety and MOT compliance. Toyota's legendary reliability extends to electrical systems, so replacement headlights typically provide long, trouble-free service matching the brand's reputation for quality and durability.

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How to Replace Toyota Front Bumper

Replacing a Toyota front bumper is achievable in 60-90 minutes depending on model and specification. This process covers Hilux, HiAce, Proace, and Land Cruiser models, though specific mounting points vary between the rugged pickup and 4x4 models versus commercial vans.

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. Most Toyota models have 4-6 bolts or screws securing the bumper at the top. On Hilux pickups and Land Cruiser 4x4s, these are typically 10mm or 12mm bolts easily accessible from above, positioned behind the grille area. On Proace and HiAce vans, expect similar straightforward fixings across the top of the bumper. Remove all upper fixings systematically and keep them organized for reassembly. Toyota's practical engineering ensures accessibility.
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. On Hilux and Land Cruiser models with their robust construction and generous wheel arch clearances, access is straightforward. Remove or release 3-5 plastic clips or screws securing the front section of the liner to expose side bumper mounting points. Toyota uses simple push-in clips that release by pressing the center pin first, then pulling the outer portion. Repeat on both sides for complete access to all mounting points.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-4 bolts or screws securing each side of the bumper to the chassis or body. These are usually 10mm or 12mm bolts on Toyota models. Remove all side fixings on both driver and passenger sides. The straightforward design reflects Toyota's maintenance philosophy focused on ease of service and repair. Keep track of which fixings came from which location, though Toyota's consistent engineering typically means fixings are interchangeable.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. On Hilux pickups and Land Cruiser 4x4s, the high ground clearance makes underneath access easier than on conventional vans. Locate and remove all screws and clips securing any engine undertray and the lower edge of the bumper. Toyota typically uses 8-12 fixings along the bottom edge depending on model. These may be bolts, screws, or plastic push-in clips depending on model year and variant. The robust construction means mounting points are substantial and clearly visible.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors. This includes fog lights if fitted on higher-specification models, parking sensor connections if equipped with parking assist systems on newer Proace or Land Cruiser models, and any additional connections for cameras or other integrated systems. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting. Toyota electrical connectors are typically high-quality with positive locking mechanisms, but handle with appropriate care.
6. Release the bumper side clips and mounting tabs. Toyota bumpers are secured by clips or brackets on each side that engage with the body panels or chassis. With all fixings removed, firmly but gently pull the bumper forward from one corner while a helper supports the opposite side, particularly on larger Hilux and Land Cruiser bumpers. You may need to wiggle slightly to release the clips. Listen for clicks as clips disengage. On Hilux and Land Cruiser models, the body-on-frame construction means bumper mounting points are extremely robust, designed to withstand off-road impacts and heavy use.
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. Toyota bumpers vary significantly in size and weight, with Hilux and Land Cruiser bumpers being substantial due to protective construction, while Proace and HiAce van bumpers are more manageable. A second person is strongly recommended for pickup and 4x4 models due to size and weight. Place the removed bumper on a protected surface to avoid scratching the painted surface or damaging any integrated components like fog lights or sensors.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, fog light surrounds, towing eye covers, or trim pieces from the old bumper if not fitted to your replacement. On Hilux and Land Cruiser models used for off-road or heavy-duty work, inspect mounting points on the chassis for damage and address any issues before fitting the new bumper. 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 if fitted, ensuring each connector clicks firmly. Systematically secure with all screws, bolts, and clips in reverse order of removal, following proper torque specifications. Test all electrical functions including fog lights, parking sensors, and any integrated lighting before final assembly. Check panel gaps are even on both sides and bumper sits flush with surrounding bodywork. Toyota's quality control means replacement parts typically fit precisely without extensive adjustment, reflecting the brand's manufacturing excellence.

Top Tips: Toyota bumpers are designed for practical replacement, reflecting the brand's focus on serviceability and owner maintenance. On Hilux and Land Cruiser models used for off-road driving, towing, or challenging conditions, check for mud and debris buildup behind the bumper before fitting the replacement, and inspect mounting brackets for fatigue or damage from heavy use. The body-on-frame construction on pickups and 4x4s means bumper mounting points are exceptionally strong and durable. When refitting parking sensors on newer models, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. On Proace vans sharing platforms with PSA vehicles, replacement bumpers from Citroën Dispatch or Peugeot Expert may physically fit but verify Toyota-specific mounting points and electrical connections before purchasing. Toyota's excellent UK parts availability through the strong dealer network means sourcing genuine replacement bumpers is straightforward, and the brand's legendary reliability extends to body components providing long service life. Check all panel gaps between bumper and wings are even before final tightening, and verify all electrical systems function correctly including any integrated safety features.

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Common Toyota Van Parts Problems & Solutions

Toyota commercial vehicles are renowned for exceptional reliability and consistently rank among the most dependable brands globally. What Car? 2025 placed Toyota fourth overall among all manufacturers, Driver Power 2024 ranked Toyota eighth with only 18% of owners reporting faults in the first year, Warranty Solutions Group 2025 confirmed Toyota as third most reliable brand in the UK, and the Warrantywise 2024 Reliability Index crowned the Toyota Yaris as the most reliable used car with an 89/100 score while the Hilux also ranked in the top 10. However, certain components can experience specific issues depending on model. Here are the most commonly reported Toyota commercial vehicle problems based on verified data from UK owners, mechanics, and industry specialists.

HiAce Common Problems (2001-2012 UK Models):

• Overall Reliability Assessment - Almost Bulletproof: The Toyota HiAce earned an exceptional reputation during its UK sales period from 2001-2012, with reviewers describing it as almost bulletproof reliability. The D-4D diesel engines are under-stressed and over-engineered, bodies are well rust-proofed, and interiors are hardwearing standing up to severe commercial use. Real HiAces in good condition with proper maintenance can easily exceed 300,000 miles, testament to robust engineering. Globally, the HiAce is one of the world's best-selling vans across multiple decades, widely used in developing countries where reliability and serviceability are paramount. This exceptional durability stems from Toyota's conservative engineering philosophy prioritizing longevity over cutting-edge technology.
• Injector Problems: Despite overall excellent reliability, HiAce diesel models can experience injector issues after high mileage. Symptoms include rough idle, smoke from the exhaust particularly black or white smoke, and poor fuel economy as the engine runs inefficiently. Injectors clog or wear out after high mileage, often exacerbated by poor fuel quality or infrequent servicing. Repair involves cleaning or replacing faulty injectors. Costs range from £250-£400 per injector, or £900-£1,600 for a full set of replacements. Preventative measures include using high-quality diesel fuel from reputable suppliers, replacing fuel filters according to service schedule, and using fuel system cleaner additives periodically. Regular servicing catches injector degradation early before complete failure.
• Turbocharger Failures: High-mileage HiAce models can experience turbocharger problems. Symptoms include loss of power particularly under acceleration, whistling noise from the engine bay, and blue or black smoke from the exhaust. Turbo failures stem from high mileage wear, oil contamination from extended service intervals, or poor servicing practices. Repair involves rebuilding or replacing the turbocharger. Costs range from £1,000-£2,000 depending on whether rebuild or replacement is needed. Prevention includes changing engine oil and filter strictly according to schedule using correct specification oil, allowing turbo to cool before shutting engine after hard driving, and addressing any oil leaks immediately. Regular servicing protects the turbocharger.
• DPF (Diesel Particulate Filter) Problems: HiAce diesel models equipped with DPF systems can experience blockages. Symptoms include warning lights on the dashboard indicating DPF issues, reduced power as the engine enters limp mode, and increased fuel consumption during regeneration attempts. DPF problems arise from vehicle design and driving habits, particularly short journeys preventing proper regeneration. Solutions include forced regeneration at a garage, DPF cleaning services, or in severe cases DPF replacement costing several hundred pounds. Prevention involves regular longer journeys at sustained speeds allowing natural regeneration, monitoring DPF warning lights and addressing immediately, and using correct specification diesel engine oil.
• Clutch and Gearbox Issues: Both manual and automatic gearbox HiAce models can develop transmission problems after high mileage or heavy use. Manual gearbox symptoms include difficulty changing gears, grinding noises, or high biting point indicating clutch wear. Automatic gearbox symptoms include rough or delayed gear changes, and slipping between gears. Clutch replacement costs £400-£800 depending on labor rates. Automatic gearbox issues may require fluid changes, solenoid replacement, or major overhaul costing £800-£2,000. Regular transmission servicing extends component life significantly.
• Rust Formation: Older HiAce models particularly those from early 2000s can develop rust, especially around wheel arches and undercarriage areas. While Toyota rust-proofing is generally good, vehicles used in coastal areas with salt exposure or those subjected to harsh winter conditions can develop corrosion. Preventative treatment with wax-oiling the undercarriage annually, regular washing to remove road salt, and addressing minor rust spots immediately prevents spread. When buying used HiAce vans, thorough inspection for rust is essential as bodywork repairs can be expensive.
• Airbag Non-Deployment Issues: Some HiAce models experienced problems with airbags failing to deploy during collisions, a serious safety concern. This can stem from sensor malfunctions, electrical module failures, or previously-deployed airbags not replaced when buying used. When purchasing used HiAce vans, verify airbag status and history. Any airbag warning lights should be investigated immediately by qualified technicians. Regular safety system checks as part of servicing ensure airbag systems function correctly.

Proace Common Problems (2013+ Models):

• Badge-Engineered Platform Sharing: The Toyota Proace is badge-engineered from PSA Group, sharing its platform, chassis, driveline, and body panels with the Citroën Dispatch, Peugeot Expert, and Fiat Scudo. While Toyota charges a premium of approximately £2,000-£3,000 over mechanically identical PSA equivalents, buyers pay for Toyota's aftersales reputation and warranty coverage rather than unique Toyota engineering. The PSA and Ford-developed engines and transmissions are reliable but inherit some common weaknesses from the French-built platform. Parts interchangeability exists with PSA models but verify Toyota-specific components before purchasing. This platform sharing is common in the commercial vehicle industry due to high development costs and limited market volumes.
• EGR Valve Clogging: In Proace diesel engines, the EGR (Exhaust Gas Recirculation) system can become clogged with carbon deposits over time. Symptoms include reduced power as the engine struggles, increased fuel consumption, and engine management warning light illuminating. EGR valve problems can cause rough running and poor performance. Solutions include EGR valve cleaning, replacement if severely clogged, or in some cases EGR delete (check legality). Costs range from £200-£600 depending on whether cleaning or replacement needed. Prevention involves regular longer journeys at sustained speeds, quality diesel fuel, and proper servicing intervals.
• DPF (Diesel Particulate Filter) Problems: The Proace suffers particularly from DPF issues, with the DPF and engine management system not burning off combustion deposits efficiently. Many Proace vans undergo more frequent regenerations, produce white diesel smoke during regeneration, use extra fuel during regeneration cycles, and enter limp mode when DPF becomes severely blocked. This problem appears worse on 2016-2018 models compared to 2019-2020 models which showed improvement. Solutions include forced regeneration, DPF cleaning, or replacement. Prevention involves regular motorway driving allowing natural regeneration, monitoring warning lights, and using correct specification oil.
• Injector Problems: Proace diesel models can experience injector issues. Symptoms include rough idling, smoke from the exhaust, and loss of power. Clogged or worn injectors often result from poor fuel quality or age. Repair involves injector cleaning or replacement. Costs range from £250-£400 per injector, or £1,000-£1,600 for a full set. Using high-quality diesel and regular servicing prevents injector problems. Clean fuel system helps avoid expensive repairs.
• AdBlue System Issues: Modern Proace diesel models equipped with AdBlue emission control systems can experience problems. Symptoms include warning lights, reduced power, and inability to restart if AdBlue runs empty. AdBlue system faults can stem from sensor failures, poor-quality AdBlue fluid, or system contamination. Solutions include refilling AdBlue, sensor replacement, or system diagnostics and repair. Use only high-quality AdBlue fluid and top up before empty to prevent issues.
• Manual Gearbox Notchiness: Proace manual transmission models can feel notchier than expected, with gear selection feeling imprecise. While not a fault as such, the gearbox characteristics are less refined than some competitors. Symptoms include stiff gear changes particularly when cold, imprecise gear selection, and reluctance to engage gears smoothly. Regular gearbox oil changes improve shift quality. Using correct specification transmission fluid is essential. This characteristic reflects the PSA heritage rather than typical Toyota refinement.
• Electrical Problems: Proace vans can encounter electrical issues including central locking system problems that may act up at inconvenient times, failing to lock or unlock reliably. Other electrical faults include minor sensor issues and dashboard warning lights. Solutions involve diagnostics to identify specific faults, replacing faulty components, and checking electrical connections for corrosion. While less common than diesel engine issues, electrical problems can be frustrating.
• Suspension Harshness: The Proace suspension can display brittleness particularly on the rear shocks. When unladen, the ride can be harsher than expected, especially over poor road surfaces. This is a characteristic of vans designed to carry loads rather than a fault. Upgrading to premium replacement shocks can improve ride quality. When loaded, the suspension performs better. Regular inspection and replacement of worn suspension components maintains ride quality and handling.

Hilux and Land Cruiser Common Problems:

• Exceptional Overall Reliability: Both Hilux and Land Cruiser models are legendary for extreme reliability and durability. The Hilux consistently ranks in Warrantywise top 10 most reliable used vehicles, while Land Cruiser is renowned globally as the most reliable vehicle for extreme conditions. These models can easily exceed 300,000-400,000 miles with proper maintenance thanks to under-stressed, over-engineered components and conservative tuning. Used by United Nations, aid organizations, and governments worldwide because they start reliably in any climate and keep running despite minimal maintenance. Top Gear famously attempted to destroy a Hilux through drowning, fire, demolition, and dropping from a crane, yet it continued running. This exceptional reputation means fewer common problems compared to conventional vehicles.
• DPF Issues on Modern Diesel Models: Newer Hilux and Land Cruiser diesel models equipped with DPF systems can experience similar blockage issues as other diesels. Symptoms include warning lights, reduced power, and increased fuel consumption. Prevention involves regular longer journeys and proper servicing. These models are often used for towing or off-road work which helps DPF regeneration.
• Rust on Older Models: Very old Hilux and Land Cruiser models particularly those from 1990s and early 2000s can develop rust on chassis and body, especially on vehicles used in coastal areas or harsh winter conditions with salt exposure. Later models have improved rust protection. Regular inspection and preventative treatment essential on older examples. When buying used, thorough rust inspection of chassis and body critical.
• Injector and Fuel System Issues: High-mileage diesel examples can experience similar injector wear as other Toyota diesels. However, the robust D-4D engines typically last longer between issues compared to competitors. Regular servicing and quality fuel maximize longevity. Costs for repairs similar to other Toyota diesels but needed less frequently.

Toyota Reliability Assessment:

Exceptional Reliability Leadership: Toyota's reliability is outstanding and consistently proven across multiple independent surveys and decades of real-world use. What Car? 2025 placed Toyota fourth overall among all manufacturers. Driver Power 2024 ranked Toyota eighth overall with only 18% of owners reporting faults in the first year, improving from fourteenth place in 2023. Warranty Solutions Group 2025 confirmed Toyota as third most reliable brand in the UK analyzing over 15,000 authorized claims. Warrantywise 2024 Reliability Index crowned the Toyota Yaris as the most reliable used car in the UK with an 89/100 score, while the Hilux also ranked in the top 10. Auto Express Driver Power 2024 saw Toyota dominate with three category wins including Yaris supermini, Corolla compact family car, and RAV4 mid-to-large SUV. This consistency across surveys and vehicle types demonstrates Toyota's systematic approach to quality, durability, and reliability extending across the entire model range from small cars to heavy-duty commercial vehicles.

Industry-Leading Warranty Coverage: Toyota offers an industry-leading warranty of up to 10 years or 100,000 miles, comprising three-year initial manufacturer warranty followed by up to seven years of service-activated warranty. This exceptional coverage is unmatched in the commercial vehicle sector and demonstrates genuine confidence in long-term durability. For commercial operators, this warranty provides valuable protection against unexpected repair costs during critical vehicle life. The service-activated warranty encourages proper maintenance which further extends vehicle life.

Best Practices for Toyota Commercial Vehicle Ownership: To maximize Toyota reliability and longevity, follow these recommendations. Adhere strictly to service schedules using genuine Toyota parts or quality equivalents. For diesel models, undertake regular longer journeys to facilitate DPF regeneration. Use high-quality diesel fuel from reputable suppliers and replace fuel filters according to schedule. On older HiAce models and classic Hilux or Land Cruiser vehicles, inspect for rust regularly and treat proactively. For Proace models sharing PSA platforms, be aware of common PSA issues like EGR and DPF problems and address promptly. Change engine oil and transmission fluid at recommended intervals using correct specifications. Inspect and replace worn suspension and brake components before they cause further damage. For Hilux and Land Cruiser models used off-road or for towing, inspect chassis and underbody components regularly for damage or fatigue. When buying used Toyota commercial vehicles, prioritize examples with full Toyota dealer service history and verify maintenance has been performed correctly. Despite minor issues on specific models, Toyota's exceptional reliability makes these vehicles outstanding long-term ownership propositions combining legendary durability with strong resale values and low total cost of ownership. The brand's consistent reliability leadership spanning decades provides confidence for commercial operators requiring dependable transport.

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