How to carry out replacement: Headlights 112 CDI 2.2 (638.094) Mercedes Vito W638
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Change Mercedes Vito W638 110 CDI 2.2 (638.094) Headlights yourself – manuals and video tutorials

How to change headlights on MERCEDES-BENZ Vito Van (W638) – replacement guide

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Download your free tutorial and fix MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094) problems yourself Download for free 2.77 MB Headlights for Mercedes Vito W638 Shop now
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Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094), MERCEDES-BENZ VITO Box (638) 110 CDI 2.2 (638.094), MERCEDES-BENZ VITO Box (638) 108 CDI 2.2 (638.094), MERCEDES-BENZ VITO Box (638) 114 2.3 (638.034, 638.094), MERCEDES-BENZ VITO Box (638) 113 2.0 (638.014, 638.094), MERCEDES-BENZ VITO Box (638) 110 D 2.3 (638.074, 638.078), MERCEDES-BENZ VITO Box (638) 108 D 2.3 (638.064, 638.068) … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Headlights for VITO Box (638) and other MERCEDES-BENZ models
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Tools
Replacement: headlights – MERCEDES-BENZ VITO Box (638). List of the tools you'll need:
Electronic spray
Round-nose pliers
Phillips screwdriver
Fender cover
Buy tools
Replacement: headlights – MERCEDES-BENZ VITO Box (638). AUTODOC experts recommend:
  • The replacement procedure is identical for the right and left headlight.
  • All work should be done with the engine stopped.
Replacement: headlights – MERCEDES-BENZ VITO Box (638). Take the following steps:
  1. Step 1
    Switch off the ignition.
    Step 2
    Open the hood.
    Step 3
    Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
    Step 4
    How to change Headlights on Mercedes Vito W638 1997 - free PDF and video manuals
    Unscrew the radiator grille fastener. Use a Phillips screwdriver.
  2. Step 5
    How to replace MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094) 1998 Headlights - step-by-step manuals and video guides
    Remove the radiator grille.
  3. Step 6
    Mercedes Vito W638 110 CDI 2.2 (638.094) 1999 Headlights replacement: free workshop manuals
    Remove the fastener of the turn indicator light. Use round-nose pliers.
  4. Step 7
    Changing Headlights on MERCEDES-BENZ VITO Box (638) 108 CDI 2.2 (638.094) 2000 by yourself
    Remove the turn indicator light.
  5. Step 8
    How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.064, 638.068) 2001 Headlights - online easy-to-follow instructions
    Unplug the connectors of the headlights.
  6. Step 9
    How to replace Headlights on MERCEDES-BENZ VITO Box (638) 2002: download PDF manuals and video instructions
    Detach the vacuum hose from the headlight adjuster. Use round-nose pliers.
  7. Step 10
    How hard is it to do yourself: Headlights replacement on Mercedes Vito W638 114 2.3 (638.034, 638.094) 2003 - download illustrated guide
    Unscrew the headlight fasteners. Use a Phillips screwdriver.
  8. Step 11
    Need to know how to renew Headlights on MERCEDES-BENZ VITO 1997? This free workshop manual will help you to do it yourself
    Remove the headlight.
  9. Step 12
    Changing of Headlights on Mercedes Vito W638 1998 won't be an issue if you follow this illustrated step-by-step guide
    Detach the retainer of the headlight protective cover.
  10. Step 13
    MERCEDES-BENZ VITO 110 CDI 2.2 (638.094) Headlights replacement: online guides and video tutorials
    Remove the headlight rear cover.
  11. Step 14
    Replacing Headlights on Mercedes Vito W638 2000 112 CDI 2.2 (638.094) by yourself
    Unplug the connectors of the headlight bulbs.
  12. Step 15
    VITO Box (638) 108 D 2.3 (638.064, 638.068) 2001 Headlights DIY replacement workshop manual
    Detach the retainers and remove the bulbs from the headlight.
    Replacement: headlights – MERCEDES-BENZ VITO Box (638). Professionals recommend:
    Avoid touching the bulb glass. The finger marks left on it may cause failure.
  13. Step 16
    How to change Headlights on MERCEDES-BENZ VITO Box (638) 2002 - tips and tricks
    Install the bulbs into their mounting seats in the new headlight, and attach the retainers.
  14. Step 17
    Step-by-step recommendations for DIY replacement Mercedes Vito W638 2003 108 D 2.3 (638.064, 638.068) Headlights
    Plug in the connectors of the headlight bulbs.
  15. Step 18
    DIY replacement of Headlights on MERCEDES-BENZ VITO Box (638) 110 D 2.3 (638.074, 638.078) 1997 is not an issue anymore with our step-by-step tutorial
    Install and secure the headlight rear cover.
  16. Step 19
    How to change Headlights on Mercedes Vito W638 1997 - free PDF and video manuals
    Attach the retainer of the headlight protective cover.
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