Minivan Maintenance Mercedes Vito 1 (W638)

Scheduled vehicle maintenance
After 15,000 km Engine change engine oil and oil filter, check for leaks; checking for leaks in the cooling system, checking the coolant level and the condition of the...

Checking the drive belts
Figure 1.1. Checking drive belts. 1. Turn the ignition key to the "OFF" position. 2. Place the gear shift lever in the "N" position on a manual transmission (in the "P"...

Replacing the alternator drive belt
Removal 1. On engines 111: secure the tensioner rocker arm 2 and tension pulley 3 from moving in the direction of rotation (see figure 1.8). Figure 1.8. Loosening of the...

Cooling system
Checking and topping up the coolant Caution! Do not open the radiator cap if the temperature in the system is above 90°C. After cooling down for a while, open the cap...

Changing engine oil and oil filter
Figure 1.14 a. Changing engine oil on engine 111. 1. Oil level indicator, 2. Filler plug, 3. Drain plug, 4. Filter element, 5. Container for draining oil. Figure 1.14 b....

Replacing spark plugs (only on engines 111.948 and 104.900)
Engines 111.948 1. Turn off the ignition. 2. Disconnect and remove the intake pipe 1 from the intake manifold (see figure 1.18a). Figure 1.18 a. Disconnect and remove...

Replacing the fuel filter
Engines 111.948 and 104.900 1. Turn off the ignition. 2. Open the fuel tank cap to relieve fuel pressure. 3. Clamp the rubber tubes 2 connected to the filter 1 (see...

Replacing the air filter element
1. Disconnect the intake pipe 1 from the air filter (see figure 1.22a). Figure 1.22 a. Disconnect the intake pipe. 2. Remove the upper part of the air filter 2. 3....

Checking the operation of indicator and signal lights, horn, multi-function switch, windscreen wipers and washers
Checking the operation of indicator and signal lights 1. Turn the ignition key to position "2" and apply the parking brake. The following indicator lights should come...

Changing oil in a manual transmission
Caution: Always drain the oil when the gearbox is warm. 1. Wipe the surface near the drain 2 and filler 1 plugs (see figure 1.31). Figure 1.31. Changing the oil in a...

Automatic transmission oil change
1. Wipe the surfaces around the filler 1 and drain 2 plugs (see figure 1.32). Figure 1.32. Drain 2 and filler 1 plugs of the automatic transmission. 2. Unscrew the...

Checking the steering
Checking the Power Steering Fluid Level 1. Remove cap 1 from the power steering fluid reservoir (see figure 1.34). Check the cover seal for damage and replace it if...

Checking the brake system
Checking the brake fluid level 1. Check the brake fluid level in the reservoir. It should be between the "MIN" and "MAX" marks (slightly above the "MIN" mark) (see...

Checking tire pressure
The tire pressure should be changed by 0.1 bar for every 10°C change in temperature. For example, if the room temperature is 20 and the outside temperature is 0°C, then...

Front crankshaft oil seal
Replacement 1. Lock the flywheel with locking device 3 (see figure 2.30). Figure 2.30. Front crankshaft oil seal: 1. Groove pulley of the crankshaft, 2. Seal, 3. Locking...

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Vito 1 (1996-2003)