Mercedes Vito and Viano W639 (2003-2014): known problems and buying guide

Built: 2003–2010
Median price: €5,700
Listings: 670
Running cost per month: €551–€637
Power: 95–204 PS (70–150 kW)
Reliability: 3/5
DIY: 3/5

A workable van if the body is sound, so check rust and injector leaks before anything else.

Updated 26 October 2026

All versions

Variant	Running cost per month	Median price	Listings	Fuel	Engine codes	Gearbox	Production years
Kombi lang 111 CDI, 115 PS, 6-speed manual, rear-wheel drive Research	€551	€5,900	115	Diesel	646.980	Manual (6)	2006–2010
Kombi lang 115 CDI, 150 PS, 6-speed manual, rear-wheel drive Research	€566	€5,900	110	Diesel	646.982	Manual (6)	2003–2010
Kombi lang 115 CDI, 150 PS, 5-speed automatic, rear-wheel drive Research	€586	€6,660	101	Diesel	646.982	Automatic (5)	2003–2010
Kombi lang 115 CDI, 150 PS, 5-speed automatic, all-wheel drive Research	€637	€6,660	101	Diesel	646.982	Automatic (5)	2006–2010
Kombi lang 109 CDI, 95 PS, 6-speed manual, rear-wheel drive Research	€565	€4,399	65	Diesel	646.980	Manual (6)	2006–2010
Kombi lang 120 CDI, 204 PS, 5-speed automatic, rear-wheel drive	€636	€6,600	62	Diesel	642.990	Automatic (5)	2006–2010

At a glance

Covers: Vito and Viano W639, 2003 to 2014, before and after the 2010 facelift. The Viano is the same van with a passenger body.
Reliability: 3/5. Engines usually cope with high mileage, but injector leaks and rust cost money.
DIY: 3/5. Checks and simple repairs are easy, but coding after injector or ECU work needs Mercedes XENTRY software.
Biggest risks: injector leaks on the OM646 diesel, and rust at the tailgate, sills and sliding door.
Prefer: facelift vans (2010 on) with a dry body and oil changed on time. Avoid: pre-2006 vans with rust, and cars with fumes at the injectors or oil at the oil cooler.

Engines and gearboxes

OM646 2.2 CDI (to 2010): injector leaks are the known fault. See the table below.
OM651 2.1 CDI (113 and 116 CDI, from 2010): see the OM651 guide for its timing chain and injector issues.
OM642 3.0 V6 CDI (120 and 122 CDI, Viano 3.0 CDI): the oil cooler seal can leak, and the swirl flap actuator can fail.

Known issues

Issue	Affects	Typical km	Repair cost
Injector leaks and carbon build-up	OM646 2.2 CDI, to 2010	Not stated	No confirmed price
Body rust at tailgate, sills and sliding door	All cars; worst before 2006	Not stated	No confirmed price
Oil cooler seal leaks	OM642 3.0 V6 CDI	Not stated	No confirmed price
Swirl flap actuator faults	OM642 3.0 V6 CDI	Not stated	No confirmed price

Before you buy

Injectors (OM646): start the engine cold and listen for rough running. Smell for fumes and look for black carbon at the injector seats. A workshop test measures the return flow from each injector. Bad result: a leaking injector, which is replaced on its own.
Rust: on a lift, check the tailgate, sills, sliding door bottom edge, door edges and bonnet edge for bubbles, soft metal or holes. Bad result: any holed metal. Pre-2006 vans need the closest check.
Oil cooler seal (OM642): look for fresh oil at the rear of the engine and around the oil cooler. Bad result: fresh oil.
Swirl flap (OM642): a scanner reads the fault memory for P2004 and P2006. Bad result: either code stored.
Driver airbag recall: check the VIN for open campaign 15198R on the KBA (German transport authority) recall page, or ask a Mercedes dealer. Bad result: an open campaign. Ask for proof that the work was done.

Running costs

Operational	€276
Workshop	€152
Fixed costs (tax, insurance)	€154
Total per month	€582
New-car depreciation (not included)	€55

ADAC figures for 15,000 km a year over 60 months

Market

Listings on mobile.de priced up to 50,000 EUR, 29 October 2026.

Find offers on mobile.de

Listings: 670
25th percentile: €3,900
Median price: €5,700
75th percentile: €7,500
Median mileage: 270,000 km
Median first registration: 2008
Dealer share: 31%
Price at 100,000 km: €8,474

To check a listing's price, open its variant in the table above. Each variant page has a price check.

In detail

Injector leaks and carbon build-up

Symptoms: rough running and hard starting. Loss of power. Fumes and black carbon at one injector.

Cause: injectors wear and leak inside. A poorly sealed injector lets carbon build up around it, which saps power.

Which cars: OM646 2.2 CDI (109, 111 and 115 CDI, Vito and Viano), to 2010.

Fix: replace the leaking injector on its own, not all four. After an injector or ECU change, the car needs coding with Mercedes XENTRY software. Owners report that a reseated injector kept leaking, and that the thread in the cylinder head can strip.

Test: Kfz-Dietrich gives a healthy return flow as under 25 ml/min, and over 50 ml/min as an internal leak.

Cost: no confirmed price.

Sources: RAC Drive: Vito review, Kfz-Dietrich: Vito diagnosis, MB-Club: black death on back injector, MB-Club: 2009 Vito injector

Body rust at tailgate, sills and sliding door

Symptoms: bubbling and holes at the tailgate (around the number plate and wiper), the sills, the bottom of the sliding door, the door edges and the bonnet.

Cause: not confirmed by the press. Owners blame stone chips and paint damage.

Which cars: all vans. Rust is worst on vans built before 2006, where the press and owners agree. It is much less common on facelift vans from 2010.

Fix and cost: not stated.

Sources: AutoScout24: W639 overview, Gebrauchtwagenberater: Viano W639 problems, MB-Club: W639 rust survey, PistonHeads: W639 owner views

Oil cooler seal leaks

Symptoms: oil leaks at the oil cooler seal, after years of use.

Cause: the seal hardens from long-term heat.

Which cars: OM642 3.0 V6 CDI (120 and 122 CDI, Viano 3.0 CDI).

Fix: renew the seal. No part number is confirmed.

Cost: no confirmed price.

Sources: Gebrauchtwagenberater: Viano W639 problems, Kfz-Dietrich: Vito diagnosis

Swirl flap actuator faults

Symptoms: fault codes P2004 and P2006 are stored. The swirl flap is the intake-port flap that the engine control unit opens and closes.

Cause: oil from the turbo can reach the actuator motor of the swirl flap.

Which cars: OM642 3.0 V6 CDI.