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1. Manuals
2. Brands
3. Mercedes-Benz Manuals
4. Automobile
5. viano 639 series
6. Introduction into service manual

• Page 1
  Introduction of the New Vito/Viano Model Series 639 with Code XZ1 Introduction into Service Manual – This printout will not be recorded by the update service. Status: 07 / 2010 –…
• Page 2
  Mercedes-Benz Service Introduction of the New Vito/Viano Model Series 639 with Code XZ1 Introduction into Service Manual Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart – This printout will not be recorded by the update service. Status: 07 / 2010 –…
• Page 3
  Please get in touch with the contact person responsible for your market. Product portfolio Comprehensive information about our full product portfolio can also be found in our Internet Portal. Link: http://open.aftersales.mercedes-benz.com Questions and suggestions If you have any questions or suggestions concerning this product, please write to us. Email: customer.support@daimler.com…

• Page 4: Table Of Contents

  Contents Preface Overview Brief description Gesamtsystem Overall vehicle Exterior Technical data Interior Transmission ECO Gear TSG 360 Chassis New chassis ECO power steering pump Audio and communications New Telematics Generation 2.5 List of abbreviations Index Introduction of the New Vito/Viano, Model Series 639 –…

• Page 5
  – This printout will not be recorded by the update service. Status: 07 / 2010 –…

• Page 6: Preface

  We will publicize modifications and new features as the Mercedes-Benz model series currently on the well as detailed descriptions of systems and their market. components in the relevant WIS documents. The infor-…

• Page 7: Brief Description

  Brief description Vehicle concept Basic equipment Customers who buy the new Vito/Viano model The following equipment and appointments add signif- series 639 receive an upgraded exterior design as well icant value to the basic equipment range found in the as innovative technologies and functions found for the new Vito/Viano.

• Page 8
  Brief description This brochure does not include descriptions of new features that are already found in other model series. The following table lists these new features and tells you which Introduction into Service Manuals contain descriptions of them. These Introduction into Service Manuals are available in electronic form in SDmedia on the Star Diagnosis Engine Model…

• Page 9: Exterior

  Vito’s status as a robust cargo transporter. The face of the Vito still bears the typical features of a Mercedes-Benz cargo van. The Viano’s front-end design clearly reveals its membership in the Mercedes-Benz family of people- Front view of the Vito moving vehicles.

• Page 10
  Exterior Rear view The large, vertically oriented rear lamps still represent the most prominent aspect of the Vito’s rear end design. They serve to optically emphasize the large rear opening with its deep loading sill which is neces- sary for a cargo van, and make for a striking yet func- tional tail end.
• Page 11
  Exterior Side view The lines of the vehicle in all three body lengths reveal The redesigned outside mirrors were given larger a dynamic pull towards the front. reflective surface in compliance with new regulations. The new headlamp design was accompanied by modi- fications to the fenders, which are made of steel.

• Page 12: Technical Data

  Technical data Permissible gross vehicle weight To make up for the reduced payload that would have been necessary due to the heavier engine (OM 651), chassis and bumpers, approval was gained for an increase in the permissible gross vehicle weight of the new Vito/Viano.

• Page 13: Interior

  Interior Color concept Further enhancing the perception of value is the new Vito anthracite-based interior color concept employed in In line with the new color concept, a new fabric known the new Vito/Viano. as «Kubo Black» has been developed. All interior paneling up to window level comes in the Viano color anthracite for all Vito and Viano vehicles.

• Page 14: Transmission

  They perform the following functions: with the Mercedes-Benz star. Depending on the equipment variant, the badge on • Left: Menu navigation for the multifunc-…

• Page 15
  Interior Center console control panel The upper control panel in the instrument panel has been redesigned along the lines used in the 204 model series. Push buttons with optimized haptics have replaced the rocker switches previously used. Center console control panel Open left electric load compartment sliding door ASR on/off Close left electric load compartment sliding door…
• Page 16
  Interior Seats/materials In 2008, the comfort of the seats was enhanced by altering the seat geometry and using new upholstery. Now designers have taken on the task of improving the appearance of the seats used in the Vito/Viano. This redesign is marked by the use of new materials for Vito, Viano TREND, FUN and MARCO POLO and a new design for the leather seats.

• Page 17: Transmission

  Interior Seat rails The rails consist of a single piece of extruded aluminum section in a new design with air line rail punching to transfer forces. They are no longer fitted with a removable cover and are protected by rubber profiles up to the groove to prevent damage to the rails.

• Page 18
  Interior Automatic air conditioning function The blower speed can be adjusted to five different settings using the two blower buttons. When set to zero, the bar indicator and target temperature display extinguish and a zero appears. The unit is then off. The target temperature can be specified using two buttons.
• Page 19
  Interior Sliding door Easy, ergonomic operation was at the focus of devel- opment of the sliding door’s inside handle. The previous location of the push button required the passenger to twist his or her wrist to push the button. The push button has now been moved so that the direction of operation coincides with the natural movement of the thumb.
• Page 20
  Interior Viano FUN/MARCO POLO Westfalia Color concept Floor covering in the passenger compartment In line with the new color concept, the cabinets and A high-quality TPO floor covering with HPL surface in the overhead shelf have been made lighter in color. light wood decor is offered as optional special equip- This gives the interior a more friendly appearance and ment.

• Page 21: Eco Gear Tsg 360

  ECO Gear TSG 360 The outstanding feature of the new six-speed manual This is also the first Mercedes-Benz inline manual transmission for cargo vans is its very large gear ratio transmission in which the gearshift lever is decoupled spread with a low-geared 1st gear and a 6th gear from the gear set.

• Page 22
  ECO Gear TSG 360 Technical data Unit TSG 360 Synchronization Balk-ring synchromesh Reverse gear Synchronized Maximum input torque 1st gear ratio 5.076 2nd gear ratio 2.610 3rd gear ratio 1.518 4th gear ratio 1.000 5th gear ratio 0.791 6th gear ratio 0.675 Reverse gear ratio 4.722…

• Page 23: New Chassis

  Chassis New chassis Vito and Viano model vehicles have been given a new chassis for even greater quality and comfort. The primary development aim for the new suspension tuning was to achieve greater customer orientation and to more clearly differentiate between passenger transport (crewbus/luxury MPV) and cargo transport (panel van).

• Page 24: Eco Power Steering Pump

  The hub is adorned by the blue circle with the Mercedes-Benz inscription. This rim comes standard on the Viano AMBIENTE and is available for all other vehicle variants as special equipment. 17″ light alloy rim Introduction of the New Vito/Viano, Model Series 639 –…

• Page 25: New Telematics Generation 2.5

  New Telematics Generation 2.5 Overview Innovations in the NTG 2.5 audio equipment The New Telematics Generation NTG 2.5 in the new • New operating structure Vito/Viano features a new control and display • New colors and graphics based on model series concept along with new functions similar to those in 204, 216, 221 systems found in the W 221, C 216, W 169 and in the…

• Page 26
  New Telematics Generation 2.5 Sound 5 Basic equipment: • Monochrome display • Radio • CD player (audio) • MP3 capability Special equipment: • AUX IN jack in glove compartment Sound 5 operating and display unit Audio 20 CD Basic equipment: •…
• Page 27
  New Telematics Generation 2.5 Audio 50 APS Basic equipment: • 5″ color display screen • 3-band radio tuner • DVD player (audio) • DVD arrow navigation with map display at intersections • Bluetooth capability • MP3 capability Special equipment Audio 50 operating, display and controller unit •…
• Page 28
  New Telematics Generation 2.5 Navigation Basic telephony via Bluetooth interface During Bluetooth operation, the mobile phone is not Through the exclusive use of DVD and hard disk connected to the external vehicle antenna and is not storage, navigation with the Audio 50 APS and recharged.
• Page 29
  LINGUATRONIC voice control system (VCS). The VCS lation. The preinstallation facilitates the retrofitting of is integrated in the Audio 50 APS with DVD changer a DVD entertainment system through Mercedes-Benz and COMAND APS. Accessories or by MPCs. The new LINGUATRONIC generation features new The preinstallation contains the following compo- functions and improved operating convenience.

• Page 30: List Of Abbreviations

  List of abbreviations Auto Pilot System (Navigation) Light emitting diode COMAND Cockpit Management and Data System REAR SEAT ENTERTAINMENT Deutsches Institut für Normung (German Standards Special equipment Institute) Voice control system (VCS) Digital Service Booklet Workshop Information System Euro standard (exhaust emission regulation) Introduction of the New Vito/Viano, Model Series 639 –…

• Page 31: Index

  Index Numerics 6-speed manual transmission Multifunction buttons … 20 ….13 Multifunction steering wheel … . 13 Ambiance illumination .

• Page 32
  Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart Order No. 6517 1254 02 – Printed in Germany – 07/10 – This printout will not be recorded by the update service. Status: 07 / 2010 –…

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It is not recommended to use regular tap water in the cooling system of a Mercedes Vito. Tap water contains minerals and impurities that can cause corrosion and buildup within the cooling system, potentially leading to overheating and other cooling-related issues. It is best to use distilled water or a coolant mixture specifically recommended for your vehicle to maintain the proper balance of cooling and antifreeze properties.

If you need to change a flat tire on your Mercedes Vito, start by parking the vehicle on a flat, stable surface and engaging the parking brake. Locate the spare tire, jack, and lug wrench in the trunk or under the vehicle. Loosen the lug nuts of the flat tire slightly, position the jack under the vehicle’s designated jacking point, and raise the vehicle until the flat tire is off the ground. Fully remove the lug nuts, replace the flat tire with the spare tire, hand-tighten the lug nuts, lower the vehicle, and then tighten the lug nuts using the lug wrench in a star pattern.

To check the brake fluid level in your Mercedes Vito, start by locating the brake fluid reservoir under the hood. Ensure that the vehicle is parked on a level surface and the engine is turned off. Wipe the top of the reservoir clean, remove the cap, and visually inspect the fluid level against the «MIN» and «MAX» marks on the reservoir. If the fluid level is close to or below the «MIN» mark, it is recommended to add the specified brake fluid to bring it up to the proper level. Be cautious not to introduce any dirt or contaminants into the brake fluid reservoir.

To check the transmission fluid level in your Mercedes Vito, start by parking the vehicle on a level surface and ensuring that the engine is warm. Locate the transmission dipstick, which is usually near the back of the engine. Remove the dipstick, wipe it clean, reinsert it fully, and then remove it again to read the fluid level. Make sure the fluid level is within the recommended range indicated on the dipstick.

If you need to replace a burned-out headlight bulb in your Mercedes Vito, start by opening the hood and locating the back of the headlight assembly. Depending on the specific model and year, you may need to remove a cover or disconnect wiring connectors to access the bulb. Once you have clear access to the bulb, carefully remove the connector from the back of the bulb, then twist and remove the bulb from the assembly. Insert the new bulb, ensuring it is securely in place, reconnect the connector, and if necessary, reinstall any covers or reconnect wiring connectors that were removed. Finally, test the new headlight by turning on the vehicle’s headlights.

To replace the windshield wipers on your Mercedes Vito, start by lifting the wiper arm away from the windshield until it locks in a raised position. Locate the release mechanism or tab on the wiper blade assembly, which may vary depending on the specific wiper design. Depress or release the mechanism to detach the old wiper blade from the wiper arm. Then, align the new wiper blade with the wiper arm and firmly press it into place until it clicks or locks in position. Gently lower the wiper arm back onto the windshield and repeat the process for the other wiper blade if necessary.

To reset the maintenance reminder in your Mercedes Vito, start by turning the ignition key to the «on» position without starting the engine. Within the instrument cluster, locate and press the reset button until the maintenance reminder resets or the display shows a new service interval. The exact steps may vary depending on the model year and instrument cluster design, so it is advisable to refer to the Mercedes Vito automotive repair manual for detailed instructions.

To reset the tire pressure monitoring system in your Mercedes Vito, start by ensuring that all tires are properly inflated to the recommended pressure. Then, turn the ignition key to the «on» position without starting the engine. Locate the «TPM» or tire pressure monitoring system button, usually located on the dashboard or center console. Press and hold the button until the TPMS indicator light blinks three times, indicating that the system has been successfully reset. After resetting, it is recommended to drive the vehicle for a few miles to allow the TPMS to recalibrate and confirm accurate tire pressure readings.

The frequency of air filter replacement for a Mercedes Vito depends on various factors, including driving conditions and air quality. However, as a general guideline, it is advisable to inspect and potentially replace the air filter every 15,000 to 30,000 miles or every 12 to 24 months. Regular maintenance of the air filter helps ensure proper engine performance and fuel efficiency by preventing dirt and debris from entering the intake system.

The recommended interval for fuel filter replacement in a Mercedes Vito can vary depending on the specific engine and driving conditions. However, as a general guideline, it is advisable to inspect and potentially replace the fuel filter every 30,000 to 60,000 miles or every 3 to 5 years. Regular maintenance of the fuel filter helps prevent contaminants from reaching the engine and ensures proper fuel delivery, contributing to the overall performance and longevity of your vehicle.

The recommended interval for spark plug replacement in a Mercedes Vito can vary depending on the specific engine and model year. However, as a general guideline, it is advisable to inspect and potentially replace the spark plugs every 30,000 to 60,000 miles or every 3 to 5 years. Regular maintenance of the spark plugs helps ensure proper ignition and fuel efficiency, contributing to the overall performance of your vehicle.

If your Mercedes Vito’s battery is dead, you can follow these steps to jump-start the vehicle: First, ensure that both vehicles are in park or neutral and the ignition is turned off. Connect one end of the jumper cables to the positive terminal of the working vehicle’s battery and the other end to the positive terminal of the dead battery. Then, connect one end of the second jumper cable to the negative terminal of the working vehicle’s battery and the other end to a metal, unpainted part of the engine block or vehicle frame of the dead vehicle. Start the working vehicle, let it run for a few minutes, and then attempt to start the dead vehicle. Once the dead vehicle starts, let it run for a while to recharge the battery.

For optimal performance and protection, it is recommended to use the specific engine oil grade and type as specified in the Mercedes Vito automotive repair manual. This information typically includes the recommended viscosity, such as 5W-30 or 0W-40, and the oil specification, such as API SN or ACEA C3. Following the manufacturer’s recommendations will help maintain your engine’s longevity and efficiency.

The check engine light in a Mercedes Vito typically illuminates when the vehicle’s onboard diagnostic system detects a potential issue with the engine or emissions system. It can be triggered by various factors, such as a malfunctioning sensor, a loose gas cap, or a more significant problem with the engine. To accurately diagnose the cause of the illuminated check engine light, it is recommended to consult the Mercedes Vito automotive repair manual or take the vehicle to a qualified mechanic for further inspection and diagnostic testing.