How to carry out replacement: Headlights 112 CDI 2.2 (638.194) Mercedes W638 Minibus
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Change Mercedes W638 Minibus 108 CDI 2.2 (638.194) Headlights yourself – manuals and video tutorials

How to change headlights on Mercedes Vito W638 – replacement guide

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Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194), MERCEDES-BENZ VITO Bus (638) 108 D 2.3 (638.164), MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174), MERCEDES-BENZ VITO Bus (638) 113 2.0 (638.114, 638.194), MERCEDES-BENZ VITO Bus (638) 114 2.3 (638.134, 638.194), MERCEDES-BENZ VITO Bus (638) 108 CDI 2.2 (638.194), MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) … View more

The steps may slightly vary depending on the car design.

How to change headlights / headlamp on MERCEDES-BENZ VITO 1 (W638) [TUTORIAL AUTODOC]

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Published on: 20/06/2019
16K views
All the parts you need to replace – Headlights for VITO Bus (638) and other MERCEDES-BENZ models
Alternative products
How to change Headlight on Mercedes W638 Minibus 112 CDI 2.2 (638.194) – step-by-step instructions for straightforward car repair Headlight
Tools
Replacement: headlights – Mercedes Vito W638. List of the tools you'll need:
Electronic spray
Round-nose pliers
Phillips screwdriver
Fender cover
Buy tools
Replacement: headlights – Mercedes Vito W638. 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 Vito W638. Take the following steps:
  1. Step 1
    Switch off the ignition.
    Step 2
    How to change Headlights on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Open the hood.
  2. Step 3
    Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
    Step 4
    How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Headlights - step-by-step manuals and video guides
    Unscrew the radiator grille fastener. Use a Phillips screwdriver.
  3. Step 5
    Mercedes W638 Minibus 108 CDI 2.2 (638.194) 1998 Headlights replacement: free workshop manuals
    Remove the radiator grille.
  4. Step 6
    Changing Headlights on MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194) 1999 by yourself
    Remove the fastener of the turn indicator light. Use round-nose pliers.
  5. Step 7
    How to remove MERCEDES-BENZ VITO 108 D 2.3 (638.164) 2000 Headlights - online easy-to-follow instructions
    Remove the turn indicator light.
  6. Step 8
    How to replace Headlights on MERCEDES-BENZ VITO Bus (638) 2001: download PDF manuals and video instructions
    Unplug the connectors of the headlights.
  7. Step 9
    How hard is it to do yourself: Headlights replacement on Mercedes W638 Minibus 113 2.0 (638.114, 638.194) 2002 - download illustrated guide
    Detach the vacuum hose from the headlight adjuster. Use round-nose pliers.
  8. Step 10
    Need to know how to renew Headlights on MERCEDES-BENZ VITO 2003? This free workshop manual will help you to do it yourself
    Unscrew the headlight fasteners. Use a Phillips screwdriver.
  9. Step 11
    Changing of Headlights on Mercedes W638 Minibus 1996 won't be an issue if you follow this illustrated step-by-step guide
    Remove the headlight.
  10. Step 12
    MERCEDES-BENZ VITO 108 CDI 2.2 (638.194) Headlights replacement: online guides and video tutorials
    Detach the retainer of the headlight protective cover.
  11. Step 13
    Replacing Headlights on Mercedes W638 Minibus 1998 112 CDI 2.2 (638.194) by yourself
    Remove the headlight rear cover.
  12. Step 14
    VITO Bus (638) 108 D 2.3 (638.164) 1999 Headlights DIY replacement workshop manual
    Unplug the connectors of the headlight bulbs.
  13. Step 15
    How to change Headlights on MERCEDES-BENZ VITO Bus (638) 2000 - tips and tricks
    Detach the retainers and remove the bulbs from the headlight.
    Replacement: headlights – Mercedes Vito W638. Professionals recommend:
    Avoid touching the bulb glass. The finger marks left on it may cause failure.
  14. Step 16
    Step-by-step recommendations for DIY replacement Mercedes W638 Minibus 2001 108 D 2.3 (638.164) Headlights
    Install the bulbs into their mounting seats in the new headlight, and attach the retainers.
  15. Step 17
    DIY replacement of Headlights on MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174) 2002 is not an issue anymore with our step-by-step tutorial
    Plug in the connectors of the headlight bulbs.
  16. Step 18
    How to change Headlights on Mercedes W638 Minibus 1996 - free PDF and video manuals
    Install and secure the headlight rear cover.
  17. Step 19
    How to replace MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194) 1997 Headlights - step-by-step manuals and video guides
    Attach the retainer of the headlight protective cover.
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