Mercedes-Benz viano 639 series Reference manual

Introduction of the New Vito/Viano
Model Series 639 with Code XZ1
Introduction into Service Manual
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Mercedes-Benz Service
Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart
Introduction of the New Vito/Viano
Model Series 639 with Code XZ1
Introduction into Service Manual
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Information and Copyright
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Service Manuals, System Descriptions, Function Descriptions, Technology
Guides, Technical Data Manuals and adhesive labels, can be ordered as
follows:
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Link: http://gsp-ti-shop.de
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Phone: [phone]
Fax: [phone]
Outside Germany
Please get in touch with the contact person responsible for your market.
Product portfolio
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can also be found in our Internet Portal.
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Questions and suggestions
If you have any questions or suggestions concerning this product, please write
to us.
Email: [email protected]
Fax: [phone]
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Address: Daimler AG
GSP/OIS
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D-70546 Stuttgart
© 2010 by Daimler AG
This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIS, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
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databases and online services.
Image no. of title image: N00.00-3360-00
Order no. of this publication: 6517 1254 02
07/2010
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3
Introduction of the New Vito/Viano, Model Series 639 l
Contents
Preface 5
Overview
Brief description 6
GesamtsystemOverall vehicle
Exterior 8
Technical data 11
Interior 12
Transmission
ECO Gear TSG 360 20
Chassis
New chassis 22
ECO power steering pump 23
Audio and communications
New Telematics Generation 2.5 24
List of abbreviations 29
Index 30
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5l
Introduction of the New Vito/Viano, Model Series 639
Preface
Dear Reader,
This Introduction into Service Manual presents the
most important changes and innovations found in the
new Vito/Viano.
The purpose of this manual is to inform you of the
technical highlights featured in the new Vito/Viano in
advance of its market launch. This brochure is
intended to provide information for people employed
in service, maintenance and repair, and aftersales. It is
assumed here that the reader is already familiar with
the Mercedes-Benz model series currently on the
market.
In terms of the contents, the emphasis in this Intro-
duction into Service Manual is on presenting new
features that have not yet been included in other
model series.
This brochure does not include descriptions of new
features that are already found in other model series.
You can find a list of these new features in the "Over-
view" chapter.
This Introduction into Service Manual is not intended
as an aid for repairs or for the diagnosis of technical
problems. For such needs, more extensive information
is available in the Workshop Information System (WIS)
and via Xentry Diagnostics.
WIS is updated continuously. Therefore, the informa-
tion available there reflects the latest technical status
of our vehicles.
The Introduction into Service manual presents initial
information relating to the new Vito/Viano and, as
such, is not stored in WIS. The contents of this
brochure are not updated. No provision is made for
supplements.
We will publicize modifications and new features as
well as detailed descriptions of systems and their
components in the relevant WIS documents. The infor-
mation presented in this Introduction into Service
Manual may therefore differ from the more up-to-date
information found in WIS.
All of the information relating to specifications, equip-
ment and options are valid as of the publication dead-
line in June 2010 and may therefore differ from the
current production configuration.
Daimler AG
Parts Technology and Technical Information (GSP/OI)
Note
Further information on workshop equipment, commercially available tools and special tools can be found in
the Internet at http://gotis.aftersales.mercedes-benz.com
This Introduction into Service Manual is available in electronic form in SDmedia on Release 9/2010 of the
Star Diagnosis CD.
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6Introduction of the New Vito/Viano, Model Series 639 l
Overview
Brief description
Vehicle concept
Customers who buy the new Vito/Viano model
series 639 receive an upgraded exterior design as well
as innovative technologies and functions found for the
first time in this model series.
The exterior design features of the more commer-
cially-oriented Vito have been more clearly set apart
from the Viano's passenger vehicle personality. New
accents in the interior enhance the perception of high
value and quality.
A great number of noise minimization measures have
succeeded in significantly reducing the noise level in
the interior.
The New Telematics Generation 2.5 offers an innova-
tive control and display concept with new functions
and a new design.
Innovations
•NewOM651 diesel engine
• New drive concept with the ECO start function
(OM 651) and an ECO power steering pump
(OM 651)
• New drive concept for the all-wheel drive (OM 651)
• New 6-speed manual transmission ECO
Gear TSG 360
• Modifications to the chassis
• New control concept for the rear air conditioning
system
• Introduction of the New Telematics Generation 2.5
• Bi-xenon and reflector-type headlamps with
integrated daytime running lights
• Reversing camera in combination with COMAND
• Intelligent battery sensor
• More sensors for PARKTRONIC
Coming in 09/2011
• New alternator management
Basic equipment
The following equipment and appointments add signif-
icant value to the basic equipment range found in the
new Vito/Viano.
• New body styling, including:
- Redesigned radiator grille
-Ne
wheadlampstyling
-Modifiedfenders
- Redesigned bumpers for Vito in the front and for
Viano in the front and rear
- New exterior colors
• New light alloy wheels
• New outside mirrors with larger reflective surfaces
• New color concept for the interior
• New design for the multifunction steering wheel
and gearshift lever
•Reconfigured upper control panel in the instrument
panel
• Ambiance illumination in the footwell
• Redesigned roof grab handle
• New design for seat rails
Marco Polo
• Harmonized with color concept
• Variable height adjustment for bed extension
• Second reading lamp in the pop-up roof
• New valuables compartment
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Overview
7
Introduction of the New Vito/Viano, Model Series 639 l
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
CD.
Engine Model Introduction into Service Manual
OM 651 Model 204 See Introduction into Service Manual "New Generation of
4-Cylinder Inline Engines, OM 651"
OM 642 EU5 Model 164 See "Introduction of the New GL-Class, Model Series 164"
M 272 EU5 Model 212 See "Introduction of the New E-Class, Model Series 212 Sedan"
The new Vito/Viano
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8Introduction of the New Vito/Viano, Model Series 639 l
Overall vehicle
Exterior
Front view
The most noticeable design feature of the new Vito/
Viano is the clear differentiation between the Vito and
the Viano.
The large cool air opening in the radiator grille, which
is integrated in the bumper and features muscular
dual slats, underscores the 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-
moving vehicles. The new radiator grille in the face and
the restyled bumper gives the Viano the typical
Mercedes-Benz passenger van look.
The three-dimensional bi-xenon and reflector-type
headlamps in tube design with integrated daytime
running lights represent the state of the art in road illu-
mination technology.
The wear-free LED daytime running lights are strikingly
and unmistakably integrated along the lower edge of
the bi-xenon headlamps in the toothed area. The
daytime running lights in the reflector-type headlamps
have been placed above the turn signal lamps in the
headlamp unit.
Front view of the Vito
Front view of the Viano
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9
Introduction of the New Vito/Viano, Model Series 639 l
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.
Like all detachable parts on the vehicle, the bumpers
are painted in granite gray for a look of classy moder-
nity.
The rear end design of the Viano is marked by it short
rear lamps. The rear window emphasizes the hori-
zontal, and appears wider than it really is due to the
black trim on the D-pillars. This supports the stylistic
reference to large-volume passenger cars and gives
the van a wide and low look from the rear.
Rear view of the Viano
Rear view of the Vito
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Overall vehicle
Introduction of the New Vito/Viano, Model Series 639
l
Exterior
Side view
The lines of the vehicle in all three body lengths reveal
a dynamic pull towards the front.
The new headlamp design was accompanied by modi-
fications to the fenders, which are made of steel. The
new fenders have been restyled near the headlamp
and at the transition to the bumper. The new steel
fenders enhance the vans overall aura of value and
quality.
The redesigned outside mirrors were given larger
reflective surface in compliance with new regulations.
Side view of the Vito
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Overall vehicle
11
Introduction of the New Vito/Viano, Model Series 639 l
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.
Weights Version
Vito/Viano Unit Compact Long Extra long
Permissible gross vehicle weight kg 3050
(2940*)
*Old figures
3050
(2940*)
3050
(2940*)
Payload kg 1260
(1150*)
1235
(1125*)
1210
(1100*)
Permissible gross vehicle weight kg 2800
(2770*)
2800
(2770*)
2800
(2770*)
Payload kg 1010
(980*)
985
(955*)
960
(930*)
Permissible gross vehicle weight kg 3200
(3200*)
3200
(3200*)
Payload kg 1355
(1325*)
1330
(1300*)
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12
Overall vehicle
Introduction of the New Vito/Viano, Model Series 639
l
Interior
Color concept
Further enhancing the perception of value is the new
anthracite-based interior color concept employed in
the new Vito/Viano.
All interior paneling up to window level comes in the
color anthracite for all Vito and Viano vehicles. The
carpeting is also only available in anthracite.
The instrument panel was adapted to the new color
concept. In the new Vito/Viano it comes in solid
anthracite.
Vito
In line with the new color concept, a new fabric known
as "Kubo Black" has been developed.
Viano
The color of the appointments in the Viano for the
center fields in the side wall and for the seats are orion
gray, stone and anthracite.
The Viano TREND offers a 3rd trim color with the
"Merlin" fabric in anthracite.
Color concept in the Viano TREND
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13
Introduction of the New Vito/Viano, Model Series 639 l
Interior
Multifunction steering wheel
The Viano comes standard-equipped with a rede-
signed (though unchanged in diameter) 4-spoke
steering wheel with multifunction buttons. The design
of the multifunction buttons was adapted to the one
found in passenger car models.
They perform the following functions:
The multifunction buttons are marked with an icon
indicating their function and are integrated into the
onboard lighting system.
Gearshift lever
The gearshift lever is located in an ergonomic position
in the center console in the cockpit.
The gearshift lever in manual transmission vehicles
has a knob badge showing the shift pattern, while
automatic transmission shift lever badges are adorned
with the Mercedes-Benz star.
Depending on the equipment variant, the badge on
manual shift levers may be provided with a chrome
surround. This chrome styling around the badge is
found in all automatic transmission vehicles.
•Left: Menu navigation for the multifunc-
tion display in the instrument
cluster
•R
ight: Radio volume adjustment and oper-
ation of the telephone (special
equipment)
Multifunction steering wheel and gearshift lever
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Overall vehicle
Introduction of the New Vito/Viano, Model Series 639
l
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
1 Open left electric load compartment sliding door
2 Close left electric load compartment sliding door
3 Left seat heater, 3-stage
4 Rear window wiper intermittent wipe
5 Wash with washer fluid
6 Rear window heater on/off
7PARKTRONICon/off
8 ECO start button
9 Hazard warning system on/off
10 ASR on/off
11 Central locking, overall vehicle
12 Central locking, rear compartment
13 Rear interior illumination on
14 Rear interior illumination off
15 Right seat heater, 3-stage
16 Open right electric load compartment sliding door
17 Close right electric load compartment sliding door
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15
Introduction of the New Vito/Viano, Model Series 639 l
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.
The leather seats come in fluted design with six flutes
like the X-Clusive seats, but without the ornamental
felled seams.
For the Vito a new upholstery fabric has been devel-
oped.
• Seat center: Kubo black
• Side bolsters: Solid black
This combination is offered under the sales designa-
tion "LIMA".
A third trim color is used in the Viano TREND. The
fabric called "Merlin" now also comes in anthracite in
addition to orion gray and stone. The side bolsters of
the seats are covered by imitation leather in anthra-
cite. As with for orion gray and stone, the sales desig-
nation for this combination of fabric and imitation
leather is "LEON".
For the Viano FUN and MARCO POLO, designers have
developed new fabrics with a special embossed
pattern in anthracite and blue. Sold under the sales
designation "Callao", this seat cover is available for
the Viano FUN and MARCO POLO.
The embossed design appropriately labeled "Ellipse"
radiates a contemporary, sporty feel perfectly suited
to recreational vehicles.
Fluted leather appointments in orion gray and
anthracite
Cloth/imitation leather combination "LEON" in
anthracite
Seat cover "Callao" for FUN and MARCO POLO
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Overall vehicle
Introduction of the New Vito/Viano, Model Series 639
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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. The new end caps are matched to the rail profile
and fit flush with the rail.
Should the rubber profiles become damaged or
destroyed, they can be replaced without the need to
disassemble the rail. All seat functions have been
retained.
The optimized sliders make for improved operational
safety and force transmission and prevent incorrect
positioning of the seats while minimizing the risk of
rail damage.
Rear air conditioning
Up to now, the controls for the rear air conditioning
were located in the rear compartment headliner at the
front left. In the new Vito/Viano, the rear air condi-
tioning control panel is now accessible for the driver
as well. It has been integrated into the overhead
control panel.
An amber colored display shows all the settings,
including the set temperature.
Rear vents
The rear vents have been redesigned. The slats can
now be completely closed. The air flow adjustment
range has been expanded.
The control wheels for horizontal and vertical air flow
adjustment are now located outside the slat area. The
holder for the load safety net has been given a lock-
able sliding cover.
New side wall lining has made it possible to reduce
intake noise by up to 6 dB.
Overhead control panel
1 Rear air conditioning controls and display
Seat rails
1Seatrail
2 Rubber profile
3Endcap
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17
Introduction of the New Vito/Viano, Model Series 639 l
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. The outlet air temperature is then regulated
automatically.
Air is conducted to various parts of the vehicle
depending on the operating mode. In heating mode,
air is guided to the floor, while in cooling mode air is
directed towards the ceiling.
To activate the Auto function, the "reduce blower
speed" button needs to be pressed and held (for more
than 1.2 s). While the button is pressed, the four
letters "AUTO" in the display will flash. Briefly pressing
one of the blower buttons will deactivate the Auto
function.
Heating function
The blower speed can be adjusted to five different
settings using the two blower buttons.
The outlet air temperature is not regulated. The
temperature in the rear is raised or lowered by control-
ling the temperature flap. Two buttons in the upper
control panel control the temperature flap.
For rear heating, air is only blown into the footwell
area.
Heating controls
1Lowertemperature
2 Raise temperature
3Raiseblowerspeed
4 Lower blower speed
5 Blower speed indicator
6Temperatureindicator
Automatic air conditioning controls
1 Lower target temperature
2 Raise target temperature
3 Raise blower speed
4 Lower blower speed/Auto function
5 Blower speed indicator
6 Target temperature indicator
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Overall vehicle
Introduction of the New Vito/Viano, Model Series 639
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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. This allows for better access,
a tighter grip on the handle and easier operation of the
push button.
Developers also paid special attention to the oper-
ating forces required. By reengineering the release
kinematics, it was possible to reduce the force needed
to operate the sliding door from the inside by
approximately 20 N.
Ambiance illumination
Four LEDs in the rear and two in the footwell produce
the ambiance illumination in the footwell. These LEDs
are dimmed at night, but shine at full capacity when
the door is opened to serve as additional entrance illu-
mination.
The LEDs in the restyled grab handles gently illuminate
the ceiling to produce a pleasant sense of spacious-
ness when traveling at night.
Eletric sliding door inside handle
Mechanical sliding door inside handle
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Introduction of the New Vito/Viano, Model Series 639 l
Interior
Viano FUN/MARCO POLO Westfalia
Color concept
In line with the new color concept, the cabinets and
the overhead shelf have been made lighter in color.
This gives the interior a more friendly appearance and
makes it appear roomier. The decorative strips in
black burr walnut look have been adapted to the new
color concept with side wall linings in anthracite.
The roller blinds and cabinet drawers are again silver
in color.
The Westfalia inscription in the stove cover has been
given a new chrome look.
Adjustable bed extension
The new bed extension has a number of different
settings. This allows users to find the most comfort-
able sitting or sleeping position. The height is also vari-
able, with 10 different settings to choose from.
To raise it, lift up the head section until the support
braces latch into the desired position. To lower it, first
raise the head section to the uppermost notch
(approx. 90° position). The lock will then release and
you can lower the head section back down to the hori-
zontal position.
Otherwise the bed extension works just like the old
one.
Lamps in the pop-up roof
A second 12V, 5W halogen reading lamp has been
installed in addition to the standard lamp. This allows
for two people to read in the roof bed at the same
time.
Floor covering in the passenger compartment
A high-quality TPO floor covering with HPL surface in
light wood decor is offered as optional special equip-
ment. This flooring is already very popular among
customers of the MARCO POLO Limited Edition
model.
The floor's design is reminiscent of ship planks and
gives the interior a more exclusive, spacious feel. The
fine, dark stripes form a connection with the anthra-
cite-colored carpeting in the cab and with the side wall
linings, but without detracting from the overall bright-
ness of the interior compartment.
Valuables compartment
Items of value, such as mobile phones, digital
cameras, wallets and purses, can be stored in the valu-
ables compartment well out of sight from anyone
looking in.
Compared to the glove compartment, the valuables
compartment offers greater protection, and this not
only because it is hidden beneath the driver seat. It's
door is made of metal and serves to lock the entire
compartment into the seat base. It also offers a
degree of protection against forced opening with the
aid of tools.
The lock cylinder in the compartment door is matched
with the lock of the fresh water tank so that one set of
keys can be used for both.
The valuables compartment is available as special
equipment for all Viano variants.
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