Vauxhall Van Parts UK - Quality Used & Genuine Van Parts

How to Replace Vauxhall Van Headlights

Vauxhall van headlight replacement is straightforward across Combo, Vivaro, and Movano models. Whether replacing standard halogen units or upgrading to LED headlights, this guide covers the essential steps for most Vauxhall 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 Combo vans, access is excellent due to compact engine layout. On Vivaro and Movano, the bonnet provides good clearance for headlight access. Ensure the engine is cool before starting work.
2. Disconnect all electrical connectors. Vauxhall van headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. On models with daytime running lights, there may be additional connectors. Press the release tabs carefully and pull straight out to disconnect. Note the position of each connector for correct reconnection.
3. Remove the headlight mounting screws. Most Vauxhall vans use T20 or T25 Torx screws to secure the headlight assembly. On Combo models, there are typically 2-3 screws along the top edge easily accessible once the bonnet is open. On Vivaro and Movano, expect 3-4 mounting screws with clear access from above. Remove all mounting screws completely and keep them organized for refitting.
4. Release any additional clips or retainers. Some Vauxhall van headlights use supplementary plastic clips at various points for additional security. Check the inner corner and lower edge for push-in clips that may need releasing. Work carefully as plastic clips can become brittle with age, especially on older Combo and Vivaro models.
5. Carefully remove the headlight assembly. With all screws and clips released, gently pull the headlight straight forward out of its mounting position. Vauxhall headlights slide forward on locating pins that ensure correct alignment. Support the weight as you pull to prevent dropping the unit. If you feel resistance, stop and check for missed fixings rather than forcing the headlight out.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs, carefully transfer these from the old unit. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as skin oils cause premature bulb failure. Check bulb condition and replace if necessary during headlight replacement.
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 points. Refit all mounting screws and tighten securely but avoid overtightening plastic mounting points. Reconnect all electrical connections ensuring each clicks firmly into position. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and indicators to confirm correct operation.

Important Notes: Vauxhall van headlight replacement is achievable for most DIY mechanics. When handling new headlights, never touch lens or reflector surfaces as this affects light output. After fitting, check headlight alignment using adjustment screws on the rear of the assembly. Proper alignment is crucial for optimal visibility and MOT compliance. On newer Vivaro and Movano models with advanced lighting, ensure all functions including daytime running lights operate correctly.

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How to Replace Vauxhall Van Front Bumper

Replacing a Vauxhall van front bumper is achievable in 45-90 minutes depending on model. This process covers Combo, Vivaro, and Movano models, though specific screw locations vary between generations and van sizes.

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. Most Vauxhall vans have 4-6 Torx screws or bolts securing the top of the bumper. On Combo models, these are typically T20 Torx screws easily visible once the bonnet is open. On larger Vivaro and Movano vans, expect 6-8 fixings across the top edge. Remove all upper fixings systematically and store them safely.
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 of the liner to expose side bumper mounting points. Vauxhall uses plastic push-in clips that release by pressing the center pin first, then pulling the entire clip out. Repeat this 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. These are usually T20 or T25 Torx screws on Vauxhall commercial vehicles. Remove all side fixings on both driver and passenger sides. Keep track of which fixings came from which side if they differ in length or type.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands, never work under a van supported only by a jack. Locate and remove all screws and clips securing the engine undertray and lower edge of the bumper. Vauxhall vans typically use 6-12 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 release the front section.
5. Disconnect fog lights, sensors, 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 (standard on many Vivaro and Movano models), and any additional connections for cameras or radar 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.
6. Release the bumper side clips and mounting tabs. Vauxhall van 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 to release the clips from their mounting points. Listen for clicks as clips disengage. Have a helper support the bumper if working on larger Vivaro or Movano models.
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. Combo bumpers are relatively lightweight and manageable for one person. Vivaro and Movano bumpers are larger and heavier, so a second person is recommended for safe removal. Place the removed bumper on a protected surface to avoid scratching the painted finish.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, fog light surrounds, or components from the old bumper if not fitted to your replacement part. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly in their mounting positions. Reconnect all electrical connections including fog lights and parking sensors, ensuring each connector clicks securely. Systematically secure the bumper with all screws and clips in reverse order of removal. Test all electrical functions including fog lights, parking sensors, and any camera systems before final assembly. Check panel gaps are even on both sides and adjust if necessary.

Top Tips: Vauxhall van bumpers are designed for practical replacement by fleet workshops. When refitting parking sensors, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. On models with front-mounted cameras or radar for parking assist, these may require recalibration after bumper replacement, consult a Vauxhall specialist if warning lights appear. Check all panel gaps between bumper and wings are even before final tightening. Vauxhall's manufacturing tolerances mean replacement parts typically fit well without extensive adjustment.

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Common Vauxhall Van Parts Problems & Solutions

Vauxhall vans are known for reliability, efficiency, and cutting-edge technology, making them popular choices among UK tradespeople and fleet operators. The Combo has an enviable reputation for reliability, with a Royal Mail mechanic describing it as easily the most reliable van compared to Fiat Doblo and Ford Transit Connect. However, certain components can experience specific issues across the range. Here are the most commonly reported Vauxhall van parts problems based on verified data from UK mechanics, fleet operators, and industry specialists.

DPF Blockage (Diesel Particulate Filter) - Most Common Issue:

• Affected Models: All diesel Combo (1.5, 1.6, 2.0 CDTi), Vivaro (1.6 BiTurbo, 2.0 CDTi 2014-2020), and Movano diesel models. DPF blockage is by far the most common problem affecting Vauxhall commercial vehicles, particularly those used for frequent short journeys where the engine doesn't reach optimal operating temperatures.
• Causes and Symptoms: Short trips prevent DPF regeneration cycles that burn off accumulated soot. Using incorrect oil grades and poor-quality fuel exacerbate the issue. Symptoms include DPF warning light illuminated on dashboard, reduced performance and loss of power, vehicle entering limp mode with maximum 3,000 RPM, increased fuel consumption, and rough running. If the engine management light comes on and glow plug light flashes simultaneously, you will not be able to regenerate the DPF by driving.
• Repair Costs and Solutions: Forced regeneration using diagnostic tool costs £100-£250. Chemical DPF cleaning costs £250-£500. Full DPF replacement costs £600-£1,000 depending on model. The DPF will not regenerate if engine management light is on for any fault, there's a faulty EGR valve, or fuel level is below 20 litres. When DPF fills to over 90 percent or 45 grams, replacement is required and is not covered under warranty.
• Prevention: Drive at motorway speeds at least once weekly for 20-30 minutes to allow natural regeneration. Use correct specification engine oil as cheap oil causes blocked oil lines contributing to DPF issues. Avoid excessive short journeys where possible. Address any engine faults immediately as these prevent DPF regeneration. Regular long-distance drives help keep the DPF clear of soot buildup and are essential preventative maintenance for commercial vehicles operating primarily in urban areas.

EGR Valve Clogging (Exhaust Gas Recirculation):

• Affected Models: Combo (1.3, 1.6, 1.7 CDTi), Vivaro (all diesel engines), Movano diesel models. EGR valve clogging is extremely common on Vauxhall vans, particularly those covering frequent short journeys at low speeds.
• Symptoms and Risks: Lack of power especially at low revs, black smoke on acceleration, rough idle or stalling at low RPM, engine running roughly, and increased emissions. A clogged EGR valve causes carbon buildup on injectors, inlet valves, exhaust valves, turbo, and glow plugs, which are major contributors to blocked DPF. There have been recalls for EGR valve pipe failures allowing hot exhaust gases to escape and damage nearby components.
• Repair Costs and Solutions: Specialist cleaning to remove carbon deposits costs £200-£350. EGR valve replacement costs £250-£700 depending on model and labor. After replacement, DPF regeneration is required. Using high-quality fuel, periodic use of fuel additives, and ensuring the van is driven at sufficient load and temperature helps reduce excessive soot formation.
• Prevention: Frequent short journeys worsen EGR clogging, so regular motorway driving helps keep the valve clean. Taking longer drives occasionally prevents carbon buildup. Proper maintenance and using quality diesel fuel reduce clogging rates significantly.

Turbocharger Failure (Common on Diesel Models):

• Affected Models: Combo (1.3, 1.6, 2.0 diesel), Vivaro (1.6 BiTurbo particularly affected, 1.9, 2.0 CDTi), Movano diesel models. Turbo failure causes vans to enter limp mode with severe loss of power and acceleration.
• Causes and Symptoms: Blocked oil feed pipes from cheap oil breaking down, oil contamination, bearing wear, and carbon buildup from clogged EGR valves damaging turbochargers. The 1.6 BiTurbo twin-turbo engine in Vivaro produces complex system with whining sound signaling problems. Symptoms include loss of power especially at higher speeds, whistling or whining noise from engine area, black smoke from exhaust, and van entering limp mode. Many turbo issues are caused by shorts in wiring or poor turbo pressure switch controlled by turbo pressure sensor.
• Repair Costs and Solutions: Turbocharger replacement costs £700-£1,200 including labor. Oil lines must be flushed during replacement. Always use correct oil grade and change oil on schedule to prevent premature turbo failure. Diagnostics should be run to analyze fault codes before replacement. On BiTurbo models, replacement costs are much higher than single turbo due to complex twin-turbo system.
• Prevention: Regular oil changes every 10,000 miles protect turbo and engine. Use quality oil as cheap oil causes blocked oil lines starving turbo of lubrication. Regular motorway trips help prevent turbo damage from carbon buildup.

Clutch and Gearbox Problems:

• Affected Models: Combo (1.3, 1.6, 1.7 CDTi 2005-2018 particularly affected), Vivaro (1.6 BiTurbo and 2.0 CDTi 2014-2020), older Movano models with high mileage. Manual gearbox problems are common complaints from Vauxhall van operators.
• Symptoms: Clutch slipping, difficulty changing gears smoothly, clutch juddering when pulling away, stiff gear changes, crunching noises, van jumping out of gear, rattling at idle, and clutch sticking especially in colder weather. Some owners report notchy gear changes about as crisp as a limp salad, particularly in older Combo models.
• Causes and Solutions: Worn clutch friction plate, failed dual-mass flywheel, worn synchromesh rings, damaged bearings, or stretched cables cause these issues. Repair involves replacing clutch kit including basket, plate, thrust bearing and slave cylinder, and inspecting gearbox bearings. Older Vivaro models are known for gearbox bearing failure, especially on high-mileage vans. If left unrepaired, the gearbox can seize and cause serious damage.
• Repair Costs: Clutch and flywheel replacement costs £700-£1,300 depending on model. Replacing both clutch and flywheel together saves future labor costs. Heavy use, towing, and constant stop-start driving increase risk of gearbox wear significantly in commercial applications.

Timing Chain Issues (Combo 1.5 Diesel Pre-2022):

• Critical Issue - Affected Models: Combo with 1.5 Turbo Diesel PSA motor manufactured prior to 2022. This is a serious known fault requiring urgent preventative action.
• Problem Details: The 7mm timing chain used in pre-2022 1.5 diesel Combo vans is prone to stretching and snapping. Oil filter paper elements break down and block oil ways, starving the chain tensioners of oil, causing chain stretch and eventual failure. If the chain snaps, it causes catastrophic engine damage requiring complete engine replacement.
• Solution and Prevention: Owners must get timing chain upgraded from 7mm to 8mm specification. Chain conversion costs £500-£800 but prevents engine replacement costing several thousand pounds. Ignore Vauxhall's 20,000-mile service intervals and change oil and filter every 9-12,000 miles depending on usage to prevent oil breakdown. Using quality oil and frequent changes protects the chain and tensioners. This preventative maintenance is essential for longevity.

Vivaro 2.0 DCi M9R Engine Issues:

• Specific Problem: One of the most discussed issues with Vivaro vans involves the 2.0 DCi M9R engine. These engines are susceptible to rainwater dripping from poor bonnet seal at the base of the windscreen, causing corrosion buildup between fuel injectors and cylinder head.
• Additional Problems: Known "kangarooing" effect between 2,500-3,000 RPM with noticeable stuttering. This can be caused by wiring issues, faulty pins, or connection problems that must be diagnosed. Injector leaks are common requiring replacement or repair. Address water ingress issues urgently to prevent serious corrosion damage.

Electrical Issues and Battery Problems:

• Affected Models: Vivaro particularly affected, also Combo and Movano. Various electrical issues can be troubling as they affect dash electronics, lights, windows, central locking mechanisms, and engine starting.
• Common Causes: On Vivaro, issues are often caused by poor battery connections that have corroded. The battery sits underneath a metal panel on the floor, causing exposure to elements leading to corrosion. Door central locking failures are common with faulty actuator motors or broken wiring. Spontaneous dead batteries, entertainment systems with mood swings, and windows refusing to operate are reported issues.
• Repair Costs: Door actuator replacement costs £150-£400. Battery and alternator issues range from £100-£500. Alternator failure is serious, causing loss of power and vehicle stalling. Keep wiring connections sealed to prevent electrical corrosion. Clean electrical connectors regularly to prevent corrosion-related faults.

Other Common Problems:

• Injector Leaks (Diesel Models): Common on older Combo and Vivaro diesels. Symptoms include fuel smell, rough running, and loss of power. Repair costs £300-£600 depending on number of injectors needing replacement.
• Water Leaks (Combo): Some Combo vans let water sneak into the cabin, turning the van into something resembling a leaky boat. Check door seals and bulkhead seals regularly.
• Steering Problems (Combo): Lower UJ bolts to rack in footwell take quite a battering after 4 years. Simple tightening of bolts solves irritating clonking sound.
• Brake Servo Issues: Some owners experience brakes suddenly not operating even when pressed hard. Usually caused by vacuum leak in servo, easily solved by mechanic.

Vauxhall Van Reliability Assessment:

Overall Good Reliability with Known Issues: Vauxhall vans offer good reliability when properly maintained. The Combo has an enviable reputation, with Royal Mail mechanics rating it as easily the most reliable van. Vivaro earned Gold Euro NCAP safety rating in 2024 and uses tried-and-tested Stellantis components shared with Citroen Dispatch and Peugeot Expert. However, Vauxhall as a brand ranked 23rd out of 30 manufacturers in What Car? Reliability Survey, which is disappointing. The most common issues are DPF blockages, EGR valve clogging, and turbo failures, all preventable with proper maintenance.

Critical Issues to Watch: The Combo 1.5 diesel pre-2022 timing chain issue requires immediate attention with 7mm to 8mm upgrade. DPF and EGR problems affect all diesel models but are manageable with regular long-distance driving. Vivaro 2.0 DCi M9R engine water ingress issues need urgent attention. Turbo failures are expensive but preventable with regular oil changes using correct grade oil.

Prevention and Maintenance: Change engine oil regularly every 9-12,000 miles, not 20,000-mile intervals. Drive longer distances weekly to prevent DPF and EGR issues. Keep wiring connections sealed to prevent corrosion. Inspect gearbox oil levels every 20,000 miles. Use genuine or OEM parts for reliability. Address warning lights immediately as delayed repairs become more expensive. Many Vivaro owners report vans still going strong after 300,000 miles with proper maintenance. For used van purchases, check alternators, power steering pumps, timing chain condition, and suspension carefully. Ex-lease models can be economical purchases as they require regular servicing.

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