The Vauxhall Vivaro is one of the most popular van choices for UK campervan conversions. It is built on the same platform as the Renault Trafic and Nissan Primastar (and later, the Peugeot Expert and Citroen Dispatch), which means parts are cheap, knowledge is shared, and there are three generations of the van to choose from at different price points.
This guide covers what you need to know before buying a Vivaro for conversion: which generation to choose, engine reliability, payload and dimensions, and the specific things that go wrong.
Vivaro Generations Compared
Vivaro A (2001-2014)
The first generation Vivaro was built from 2001 to mid-2014. It was available as a panel van, double cab, and crew van. The most common version for conversion is the LWB panel van (length: 5,398mm, wheelbase: 3,498mm).
Pros:
- Cheap to buy (£1,500-£5,000 depending on age, mileage, condition)
- Parts are widely available and inexpensive
- Simple mechanical layout — easy to work on for DIY conversions with basic tools
- High roof option (1,890mm internal height) — stand-up interior
- Berlingo-sized fuel economy (40-45 mpg from the 2.0 CDTi)
Cons:
- Rust. The Vivaro A rusts in the same places: rear wheel arches, door bottoms, scuttle panel (where the windscreen meets the bulkhead), and the roof seams. A Vivaro A without rust repairs is worth less. One with rust repairs is worth little more. Budget £500-£1,500 for bodywork.
- Older electrical system. No CAN bus, which is simple but means fewer aftermarket options for things like cruise control and electric windows.
- Crash safety: Euro NCAP 3-star rating. Front airbags but no curtain airbags (2006-on models have them as an option).
- The 1.9 CDTi engine (2001-2006) is underpowered for a converted van (82hp). The 2.0 CDTi (2006-2014, 90-115hp) is adequate.
Best Vivaro A engines:
- 2.0 CDTi 115 (2006-2014) — the best. Adequate power, reliable if serviced. Timing belt every 100k miles.
- 2.0 CDTi 90 (2006-2014) — same engine, detuned. Acceptable but lacks power on motorway hills.
- Avoid the 1.9 CDTi (82hp). Underpowered even before you add 500kg of conversion.
Vivaro B (2014-2019)
The second generation Vivaro was launched in mid-2014 and sold until 2019 (alongside the identical Peugeot Expert and Citroen Dispatch). This is now the sweet spot for van conversions: modern enough for decent safety and fuel economy but old enough to be affordable.
Pros:
- Much better crash safety: Euro NCAP 4-star, with seven airbags as standard
- Payload: up to 1,200kg for the panel van (varies by engine and spec)
- Fuel economy: 45-50 mpg from the 1.6 CDTi 120
- Less rust-prone than the Vivaro A (galvanised body panels)
- Towing capacity: up to 2,500kg (braked)
- AdBlue on newer models (2017+) — reduces emissions but adds complexity
Cons:
- The 1.6 CDTi engine (2014-2018) has known issues: turbo actuator failure (£300-£500 to replace), EGR cooler leaks, injector failure (common rail system). The 2.0 BiTurbo is more reliable but less common.
- AdBlue system (2017-onwards) adds a component that can fail. AdBlue heater failures (£200-£400). DPF issues on vans used for short trips.
- The infotainment system (IntelliLink) is slow and unresponsive by modern standards. Acceptable if you use your phone for navigation.
- The LWB version is 5,399mm long — only 1mm more than the Vivaro A LWB. The SWB is 4,999mm.
Best Vivaro B engines:
- 1.6 CDTi 120 (2014-2018) — best balance of power and economy. Servicing is critical. Use the correct low-ash oil (C2 spec) or DPF clogs.
- 2.0 BiTurbo 180 (2016-2019) — more powerful and more reliable. Better for heavy conversions (over 800kg). Higher tax band.
- Avoid the 1.6 CDTi 95 (underpowered) and the early 2014 1.6 CDTi 115 (harder DPF and EGR issues).
Vivaro C (2019-on)
The current generation Vivaro (also sold as the Peugeot Expert/Citroen Dispatch/Toyota Proace). It is an entirely different platform, built by PSA/Stellantis.
Pros:
- Modern safety: autonomous braking, lane keep assist, blind spot monitoring
- Fuel economy: 40-45 mpg (2.0 BlueHDi)
- Payload: up to 1,400kg (panel van)
- 8-speed automatic transmission option
- Digital dashboard and modern infotainment (phone mirroring)
Cons:
- Expensive: £15,000-£25,000 used for a 2019-2022 model
- More complex wiring for conversion (CAN bus, BCM, multiple modules)
- AdBlue and DPF are standard on all models
- The automatic transmission is expensive to repair (£3,000+)
- The 2.0 BlueHDi engine has EGR and injector issues similar to the Vivaro B
Best Vivaro C engines:
- 2.0 BlueHDi 145 (2019-on) — the standard choice. Adequate power, reasonable economy. Avoid the 2.0 BlueHDi 100 (underpowered for a conversion).
- Electric Vivaro-e (2021-on): 75kWh battery, 200-mile real-world range. Buildable as a campervan but range is limiting. Charging infrastructure improves annually but still harder than diesel for remote travel.
Vivaro Dimensions and Payload
| Model | Length | Wheelbase | Internal Height (low roof) | Internal Height (high roof) | Payload |
|---|---|---|---|---|---|
| Vivaro A SWB | 4,783mm | 3,098mm | 1,380mm | 1,890mm | 800-1,100kg |
| Vivaro A LWB | 5,398mm | 3,498mm | 1,380mm | 1,890mm | 900-1,200kg |
| Vivaro B SWB | 4,999mm | 3,275mm | 1,400mm | 1,910mm | 900-1,200kg |
| Vivaro B LWB | 5,399mm | 3,275mm (same) | 1,400mm | 1,910mm | 1,000-1,200kg |
| Vivaro C SWB | 4,959mm | 3,275mm | 1,410mm | 1,910mm | 1,000-1,400kg |
| Vivaro C LWB | 5,330mm | 3,275mm (same) | 1,410mm | 1,910mm | 1,000-1,400kg |
The LWB vs SWB choice: The Vivaro B and C have the same wheelbase in both SWB and LWB — the extra length is in the rear overhang. This means the SWB is better for manoeuvrability and parking, but the LWB has more rear storage. For a campervan conversion, the SWB is easier to park and the LWB is more comfortable for extended living. Most van lifers choose the LWB.
Payload calculation for a conversion:
- Vivaro A LWB base payload: ~1,100kg
- Subtract conversion weight: insulation (80kg), ply lining (60kg), furniture (100kg), bed (40kg), water tank (40kg full), leisure battery (30kg), you (80kg), passenger (80kg), clothes/food/gear (100kg)
- Conversion total: ~610kg
- Remaining payload for fuel/water/etc: ~490kg
Vivaro-Specific Conversion Considerations
Workshop Access (Vivaro B)
The Vivaro B has limited access to the rear wheel arches from inside. The wheel arch protrudes into the cargo area by approximately 250mm, which limits bed width to 1,400mm (SWB) or 1,500mm (LWB) if you build the bed across the van.
Solution: Build the bed lengthways (north-south) rather than widthways. A north-south bed can be full-width (1,860mm mattress). The trade-off is less living space behind the front seats.
Roof Profile (All Vivaros)
The Vivaro roof has a curved profile, which makes fitting a pop-top roof more expensive (the roof panel is not flat, so the roof flange must be custom-formed). A pop-top for a Vivaro costs approximately £200-£300 more than for a Transit Custom due to the curve.
Sliding Door (All Vivaros)
The Vivaro sliding door is on the passenger side. The door opening is 1,000mm wide and 1,800mm tall (high roof models). This is wide enough for a full-height fridge (850mm doors) and standard kitchen units (600mm). The door latch mechanism is housed in the door pillar and is known to fail (cable snaps, £50-£80 to replace).
Rust Points (Vivaro A)
If you are buying a Vivaro A, check these specific areas:
- Scuttle panel (below the windscreen). Water pools here and rusts through. Fix: clean the drain channels regularly. Replace if already rusted (welding required).
- Rear wheel arches. Rust starts behind the arch liner. Remove the liner to inspect.
- Rear door step. Water sits on the step (between the rear doors) and rusts through.
- Roof seams at the rear. The seam sealant dries out and water ingress follows. Reseal with Sikaflex.
Running Costs
| Cost | Vivaro A | Vivaro B | Vivaro C |
|---|---|---|---|
| Purchase price (good condition) | £2,000-£5,000 | £6,000-£12,000 | £15,000-£25,000 |
| Insurance (converted) | £500-£900/yr | £600-£1,000/yr | £700-£1,200/yr |
| Road tax | £290-£335/yr | £165-£335/yr | £165-£320/yr |
| Fuel (calculated) | £2,000-£2,500/yr (12k miles) | £1,800-£2,200/yr | £2,000-£2,500/yr |
| Timing belt interval | 100k miles | 100k miles | 125k miles (chain on some) |
| Clutch replacement | £400-£600 | £500-£800 | £800-£1,200 |
| Major service (annual) | £200-£350 | £250-£400 | £300-£500 |
| Total annual running cost (excluding purchase, including fuel/insurance/tax/service/tyres) | £3,000-£4,000 | £3,000-£4,500 | £3,500-£5,000 |
The Verdict
Vivaro B (2014-2019) is the best generation for a UK campervan conversion. It is modern enough for Euro 6 compliance (ULEZ-compatible in London), has decent crash safety, and can be bought for £6,000-£12,000 in good condition. The 1.6 CDTi 120 engine is adequate for a conversion if you keep the weight reasonable (under 800kg of conversion). The 2.0 BiTurbo is better for heavy builds.
Choose a Vivaro A only if your budget is under £5,000 and you are comfortable with rust repair or buying an already-rust-free body. The Vivaro A is a competent van but the rust is not a matter of if, just when.
Choose a Vivaro C if your budget is over £15,000 and you want the modern safety and convenience features. Be aware of the higher conversion complexity and the AdBlue/DPF maintenance.
The Vivaro's main advantages over a Transit Custom: cheaper purchase price, better fuel economy, and a wider community of parts and knowledge. The Transit Custom has better driving dynamics and a higher payload ceiling, but it costs more.
If you buy a Vivaro B, budget £300-£500 immediately for a turbo actuator replacement (it will fail around 80k miles) and £200-£400 for the AdBlue heater if you buy a 2017+ model. These are known costs, not surprises.
