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Sprinter (1995-2000, diesel) Vito 1 (1996-2003) Vito 2 (2003-2014, diesel) Vario 814D (1996-2003, diesel)
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  • Vario 814D (1996-2003)

Truck repair manual Mercedes Vario (512D-815DA)

The manual contains general information about the structure of the Mercedes Vario 1996-2003 and its modifications (512 D, 612 D, 614 D, 810 D, 812 D, 814 D, 814 DA, 815 DA), recommendations for maintenance, a description of possible malfunctions of all engine systems, both with and without turbocharging (2.9 liters (OM 602.984/985 LA 123 hp) and 4.2 liters (OM 904.908/914/923/936 LA, 115-150 hp)), transmission with manual or automatic gearbox, chassis, power steering, braking system with ABS, electrical equipment and body elements.

Due attention is paid to electronic control systems, including lists of fault codes. Technical advice provided in this manual will help to carry out maintenance and repairs, both at a service station and on your own..

See this manual at: russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian
General information
Maintenance
Brief history and characteristics of the truck
Instructions for performing maintenance
Scheduled maintenance
Checking the drive belts
Full list of articles in this category »
Power unit
Engines 602.984/985
Removal and installation the engine
Air filter
Intake manifold
Exhaust manifold
Full list of articles in this category »
Engines 904.908/914/923/936
Removal and installation the engine
Intake pipe — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Full list of articles in this category »
Transmission
Clutch
Removal and installation the clutch
Clutch slave cylinder
Checking the runout of the driven clutch disc
Full list of articles in this category »
Manual gearbox 711.613
Removal and installation of manual transmission
Reverse light switch
Gearbox housing
Gearshift fork guide plate
Full list of articles in this category »
Manual gearbox 710.64/66
Removal and installation of manual transmission
Front of gearbox
Rear of the gearbox
Primary shaft
Full list of articles in this category »
Manual gearbox 715.051
Removal and installation of manual transmission
Front of gearbox
Rear of the gearbox
Primary shaft
Full list of articles in this category »
Automatic gearbox 723.345
Removal and installation of automatic transmission
Centrifugal regulator of automatic transmission
Automatic transmission modulator
Automatic transmission oil cooler
Full list of articles in this category »
Power take-off box
Power take-off box (cars with manual transmission 711.613)
Disassembly and assembly of the power take-off box
Adjusting the axial clearance of the power take-off drive shaft
Power take-off output flange seal
Full list of articles in this category »
Chassis
Front suspension
Removal and installation the front suspension
Front axle hub
Steering knuckle
Front suspension spring
Full list of articles in this category »
Rear suspension
Removal and installation the rear suspension
Rear axle hub
Rear suspension spring
Replacing the rear anti-roll bar
Full list of articles in this category »
Steering
Removal and installation the steering gear
Power steering pump
Checking and adjusting the central position of the steering mechanism
Tightening torques for steering components and parts
Full list of articles in this category »
Brake system
Brake booster vacuum
Telma retarder (on models 668.322/323/352/353, 670.322/323/324/352/373/374 with code BR3)
Brake pads — removal and installation
Brake caliper
Full list of articles in this category »
Body and electrical equipment
Interior (internal elements)
Instrument panel
Central part of the instrument panel
Upper instrument panel cover
Driver's airbag
Full list of articles in this category »
Exterior (external elements)
Front wing
Front door
Hood — removal, installation and adjustment
Windscreen wiper arm
Full list of articles in this category »
Heater and air conditioner
Heater housing
Air conditioning compressor
Air conditioner condenser
Air conditioning compressor electromagnetic clutch
Full list of articles in this category »
Electrical diagrams
How to read and use electrical diagrams
Diesel fuel injection system for engines 904.908/914/923/936 on models 668, 670
Diesel fuel injection system and electronic engine control 602.984/985
Starting and charging system for engines 602.984/985 on models 667, 668, 670
Full list of articles in this category »

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Vario 814D (1996-2003, diesel) 
  • General information
  • Maintenance
  • Power unit
  • Engines 602.984/985
  • Engines 904.908/914/923/936
  • Transmission
  • Clutch
  • Manual gearbox 711.613
  • Manual gearbox 710.64/66
  • Manual gearbox 715.051
  • Automatic gearbox 723.345
  • Power take-off box
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body and electrical equipment
  • Interior (internal elements)
  • Exterior (external elements)
  • Heater and air conditioner
  • Electrical diagrams
Vito 2 (2003-2014, diesel) 
  • General information
  • User manual
  • Maintenance
  • Diesel engine OM646
  • Engine repair
  • Cooling and lubrication system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Car gearbox
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Body elements
  • Electrical equipment
  • Equipment and devices
  • Security systems
  • Electrical circuits
Vito 1 (1996-2003) 
  • General information
  • User manual
  • Maintenance
  • Petrol engines 2.0 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Petrol engines 2.8 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Diesel engines 2.3 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Diesel engines 2.2 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Chassis
  • Front suspension and wheels
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Electrical equipment
  • Equipment and devices
  • Heater and air conditioner
  • Electrical circuits
Sprinter (1995-2000, diesel) 
  • General information
  • Introduction to the guide
  • Maintenance
  • Power unit
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Front axle
  • Rear axle and cardan
  • Chassis
  • Car suspension
  • Steering
  • Brake system
  • Tires and wheels
  • Electrical equipment
  • Equipment and devices
  • Headlights and lighting
  • Power devices
  • Electrical circuits
 
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