AF83.10-S-1002AG Noise at recirculated air flap 4.11.96
MODEL 638.### ## up to 023549 with CODE (H81) Ventilation system with filter
Damage code Cause Remedy
83 033 16 Recirculated air flap malfunction 1 Remove complete instrument panel
83 033 41 with cross member and heater/air
conditioner
2 Grease control linkage
3 Cut out insulation on firewall (remove
local foam)
4 Attach wiring harness
5 Install complete instrument panel with
cross member and heater/air
conditioner
1 Control linkage
S83.10-1012-01
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AR83.25-S-1200A Removing and installing blower motor 6.2.95
MODEL 638.0 /1 /2
1 Screw
2 Instrument panel
3 Insert
4 Screw
5 Bracket
6 Instrument panel bracket
M40m45 Blower motor
M40m45.1 Blower motor connector
S83.10-2004-06
e d Removal, installation
1 Remove footwell cover on driver's side i Unhook footwell cover on one side
2 Remove fog lamp switch AR54.25-S-3251A
3 Unscrew screws (4) for bracket (5) on i Push insert (3) up until screws (4) are instrument panel bracket (6) visible.
4 Remove bracket (5)
5 Cut through cable strap on protective cap for i Installation: Replace cable strap.electric connectors on instrument panel
bracket (6)
6 Disconnect blower motor connector
(M40m45.1)
7 Unscrew screws (1)
8 Remove blower motor (M40m45) from heater
housing
9 Reinstall in opposite order
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AR83.10-S-4503A Removing and installing center air outlet 6.2.95
MODEL 638
1 Screw
2 Centre air outlet
3 Instrument panel centre cover
S68.10-2002-11
e d Removal, installation
1 Remove instrument panel centre cover (3) AR68.10-S-3430A
2 Unscrew screw (1) and remove centre air
outlet (2)
3 Install in reverse order
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AR68.20-S-2000A Removing and installing center console 20.5.99
MODEL 638.2
MODEL 638
with CODE (FF6) Front section of center console
with CODE (ZK6) Vito F (travel)
with CODE (ZK7) Motor caravan "Marco Polo"
1 Center console
2 Screws
S68.20-2500-05
e d Removing and installing
1 Unscrew screws (2)
2 Unscrew plastic nut (arrow) on right and left
side
3 Remove center console (1) toward front p When removing center console (1)
ensure that nothing is damaged.
i To facilitate removal pull center console
(1) apart slightly
4 Install in the reverse order
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AR68.10-S-3430A Removing and installing center cover on instrument panel 6.2.95
MODEL 638
S68.10-2000-09
Illustrated on model 638 except models
638.094/194/294
4 Center cover on instrument panel B34.1 Interior temperature sensor
5 Interior temperature sensor cover connection1 Screws
B34 Interior temperature sensor SX Type of switch used2 Knob
SX.1 Type of switch connector used3 Nut
e d Removal, installation
p Notes on battery All models AH54.10-P-0001-01A
1 Disconnect ground lead from battery i AR54.10-S-0005A Installation - Code radio.
- Set clock.
See@
Owner's manual.
2 Remove radio i AR82.60-S-7502A Remove with mounting frame.
3.1 Pull off knobs (2) Except models 638.094/194/294
p Do not damage parts.
4.1 Unscrew nuts (3) i Except models 638.094/194/294
5.1 Remove selector lever cover i Only on model 638.2 without code G40
(automatic transmission) and
model 638.094/194 without code G40
(automatic transmission)
i Separate cables straps
Pull selector lever cover up and off
6 Unscrew screws (1)
7 Remove center cover on instrument panel (4) p Carefully unclip to prevent damaging
retaining catches (danger of breaking)
8 Disconnect connector (SX.1) from switch i Mark connectors (SX.1) to associated (SX) switches (SX) (arows). The switch
designation (SX) and (SX.1) stand for all
other switch and connection designations
9.1 Disconnect temperature sensor connector i Only with code H06 (air conditioning) in (B34.1) model 638 except models 638.094/194/294.
i It is not necessary to remove the interior
temperature sensor cover (5).
10 Install in opposite order pInstallation : In model 638 except models
638.094/194/294 pay attention to illuminated
pin on heater/ventilation switch unit (danger
of breaking)
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AR46.10-S-0200A Removing and installing contact spiral 7.6.01
STEERING 763.000 in MODEL 638 with CODE (SA5) Driver airbag
1 Outer steering column cover
2 Inner steering column cover
4 Plastic cable pouch
S54.18-4007-03
1 Outer steering column cover
2 Inner steering column cover
3 Retaining bolt
S54.25-1003-01 S54.25-1010-01
5 Contact spiral / airbag wiring
harness
6 Retaining bolt
R5 Contact spiral
X113 Main wiring harness / airbag
contact spiral connector
X125 Contact spiral / airbag wiring
harness connector
S46.10-4001-06
e d Removing, installing
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Risk of injury when carrying out test or Store airbag units with deployment side AS91.00-Z-0001-01Aa Danger! repair work on airbag or emergency facing up; do not expose to temperatures
tensioning retractor units greater than 100 °C. Interrupt power supply
when working on such units.
1 Remove steering wheel i AR46.10-S-0100B Wheels must be in straight-ahead
position.
2 Detach outer steering column cover (1)
3 Unscrew retaining bolts (3)
4 Detach inner steering column cover (2)
5 Detach paneling under left side of instrument i Model 638.2 onlypanel
6 Cut through cable straps on plastic cable i The plastic cable pouch (4) remains pouch (4) and guide all electrical connectors fastened to the transverse rod behind the down and out of the plastic cable pouch (4) instrument panel.
i Installation: Replace cable strap.
7 Unplug connectors (X113 and X125) from
wiring harness (5) of contact spiral (R5)
8 Detach adhesive tapes, cable straps (arrow) p Route the wiring harness (5) so that no and retaining clips on wiring harness (5) in chafing or short circuits can occur.vicinity of electrical center
i Replace cable straps.
9 Unscrew retaining bolts (6) just enough to be p Unscrew retaining bolts (6) until the rotor able to remove the contact spiral (R5) housing of the contact spiral (R5) is blocked.
The retaining bolts (6) also act as an anti-
rotation device when the contact spiral is
removed.
10 Carefully remove contact spiral (R5) from p The contact spiral (R5) must never be steering shaft opened under any circumstances.
p If the contact spiral (R5) was twisted by
unscrewing the retaining bolts (6) all the way,
the center position must be reset. Refer to:@
Adjusting center position of contact spiral AR46.10-S-0200-01A
11 Install in the reverse order
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AR83.10-S-2500A Removing and installing control cables from heater/ventilation control unit 10.4.96
MODEL 638.0 /1 /2
1 Clamp
2 Control cable
3 Clamp
4 Control cable
S83.10-2005-06
e d Removal, installation
1 Remove instrument panel i AR68.10-S-1000A Only to remove control cable (2)
2 Unclip clips and unhook control cables (2) i AR83.20-S-1835A Remove control unit for heater/ventilation.and (4) from heater/ventilation control unit
3 Remove clamp (1) and unhook control cable
(2) from defrosting diffuser.
4 Remove clamp (3) and unhook control cable
(4) from gate for the interior air diffuser.
5 Remove control cables (2) and (4)
6 Reinstall in opposite order i Check carefully if the two gates open or
close completely when the control cables are
activated.
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AR54.25-S-1382A Removing and installing electrical center 21.3.95
MODEL 638
On the steering column
S54.25-1001-09
1 Cover A12.1 Electrical center (steering column switch connector)
2 Paneling A12.2 Electrical center (main power switch connector)
3 Bolt A12.3 Electrical center (frame wiring harness connector)
4 Bolt A12.4 Electrical center (frame wiring harness connector)
5 Nut A12.5 Electrical center (frame wiring harness connector)
A12.6 Connector
A12 Electrical center (without steering column switch)
e d Removing, installing
1 Disconnect ground cable of battery AR54.10-S-0005A
2 Detach cover (1)
3 Unscrew bolts (3)
4 Detach paneling (2)
5 Remove contact spiral Only with code SA5 (driver airbag) AR46.10-S-0200A
p Do not unscrew the bolts all the way. The
bolts also act as an anti-rotation device. The
contact spiral must never be opened under
any circumstances.
6 Loosen electrical center (A12) by unscrewing p Installation: Do not tilt the electrical bolt (4) and nut (5) center (A12) when tightening.
n *BA54.25-N-1001-01A
n *BA54.25-N-1002-01A
7 Unplug electrical connectors from electrical
center (A12)
8 Remove electrical center (A12)
9 Install in the reverse order
n Switches
Number Designation Model
638
BA54.25-N-1001-01A Bolt, electrical center to steering column switch Nm 4
BA54.25-N-1002-01A Nut, electrical center to steering column Nm 6
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AR54.30-S-6015A Removing and installing instrument cluster 27.1.95
MODEL 638 / / (except 638.094 /194 /294)
1 Plug connection of indicator
lamps
2 Screws
P15 Instrument cluster
P15.1 Connector
P15.2 Connector
P15.3 Connector
S54.30-1004-06
e d Removing, installing
1 Unscrew screws (2) p Do not damage instrument panel and
instrument cluster (P15).
2 Remove left air vent AR83.10-S-4740A
3 Push out instrument cluster (P15) from the p Do not damage instrument panel and rear instrument cluster (P15).
4 Release plug connections (P15.1, P15.2 and i Plug connections are color coded.P15.3) and pull off connections
5 Pull off plug connections (1) together with i Pay attention to installation position of indicator lamps indicator lamps.
6 Remove instrument cluster (P15) p Do not damage instrument panel and
instrument cluster (P15).
7.1 Connect adapter cable and adapter to i AD54.30-S-2003-04A Only if instrument cluster is replaced instrument cluster (P15) (P15).
8.1 Parameterize instrument cluster (P15) i AD54.30-S-2003-06A Only if instrument cluster is replaced
(P15).
9 Install in the reverse order
g Inspecting
10 Read out fault memory with HHT AD00.00-S-2000-03A
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AR68.10-S-1000A Removing and installing instrument panel 8.2.95
MODEL 638
S68.10-2004-09
Shown on model 638 except models
638.094/194/294
6 Bolt (only in models 638.094/194/294) 11 Cable of parking brake1 Screw
7 Fuse box 12 Bolt2 Cover of speaker
8 Release lever of parking brake 13 Bolt3 Foam rubber wedge9 Bolt 14 Bolt4 Loudspeaker
10 Cover of hood release S119 Switch off fog lamps5 Bolt
e d Removing, installing
p Notes on battery All models AH54.10-P-0001-01A
1 Disconnect ground cable of battery i AR54.10-S-0005A Installation: - Encode radio.
- Set time.
2 Remove steering column switch AR54.25-S-2801A
3 Remove instrument cluster i AR54.30-S-6015A Only in model 638 except
638.094/194/294
Remove instrument cluster i AR54.30-S-6015B Only in model 638.094/194/294
4 Remove switch of fog lights (S119) i AR54.25-S-3251A In model 638.0/1/2 except 638.294.
i AR54.25-S-3251B In model 638.294.
5.1 Detach passenger airbag i AR91.60-S-0680A Only with code SA6.
6 Remove ashtray AR82.00-S-9999A
N Remove cover of instrument panel in middle AR68.10-S-3430A
8 Remove right and left speakers (4) AR82.62-S-7833A
9 Open glove compartment lid, unclip lighting
and separate plug connection
10 Take off covers on left and right below
instrument panel
11 Detach cable of parking brake (11) and take
off release lever of parking brake (7)
12 Unscrew bolts (9), take off cover of hood i Cable for hood release can remain release (10) installed.
13 Unscrew bolts (5) i Remove foam rubber wedge (3) first of
all.
i Installation: Ensure the foam rubber
wedge (3) is correctly installed.
14 Remove screws (14) below instrument
cluster
15.1 Take out screw (6) of heater operating unit i Only in model 638.094/194/294.
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16 Unclip electrical system of airbag from
bottom part of instrument panel
17 Remove fuse box (7) i The fuse box system remains installed.
18 Take out screw (13) below the ashtray
19 Take out screw (12) behind cover of
instrument panel in middle
20 Unscrew screws (1) i Screws (1) must be pressed out on both
sides.
21 Pull out instrument panel p Pull out instrument panel carefully.
Ensure that no electric cables are damaged.
i Installation: The guide pins must engage
in the recesses (arrows).
22 Install in the reverse order
g Inspecting
23 Read fault memory, erase i See step 3 for this purpose.
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AR83.10-S-4740A Removing and installing side air outlet 20.1.95
MODEL 638.0 /1 /2
1 Left air nozzle
2 Right air nozzle
3 Installation wedge
S83.10-2007-02 S83.10-2008-02
e d Removal, installation
1 Remove air nozzles (1, 2) p Unclip air nozzles (1) and (2) at bottom
with installation wedge (3) without damaging
instrument panel.
l *110589035900
2 Reinstall in opposite order
110 589 03 59 00
Installation wedge
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AR54.25-S-2801A Removing and installing steering column switch 17.5.99
MODEL 638
S54.25-1006-09
1 Bolt 4 Bolt A12 Steering column switch
2 Windshield wiper switch 5 Upper cover S123 Cruise control switch
3 Turn signal switch 6 Bolt
e d Removing, installing
1 Disconnect ground cable of battery i AR54.10-S-0005A Installation: -Code radio.
-Set time.
p Notes on battery All models AH54.10-P-0001-01A
2 Remove steering wheel Without code SA5 (driver airbag) AR46.10-S-0100A
With code SA5 (driver airbag) AR46.10-S-0100B
3 Remove electrical center AR54.25-S-1382A
4 Unscrew bolts (1)
5 Unscrew bolts (4) from upper cover (5)
6 Remove upper cover (5) i Move turn signal switch (3) and
windshield wiper switch (2) to the bottom
positions to facilitate removal.
7.1 Unplug connector from cruise control switch Only with code MD0 (cruise control for
(S123) manual transmission) or
code MD9 (cruise control for automatic
transmission)
8 Remove steering column switch (A12) p Installation: Move turn signal switch (3)
to neutral position so that the reset tab is not
damaged when the steering wheel is fitted.
9 Unscrew bolt (6) from cruise control switch i Only with code MD0 (cruise control for (S123) manual transmission) or
code MD9 (cruise control for automatic
transmission)
10 Detach cruise control switch (S123) from i Only with code MD0 (cruise control for steering column switch (A12) manual transmission) or
code MD9 (cruise control for automatic
transmission)
11 Install in the reverse order
g Checking
12 Carry out function test
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AR46.10-S-0100A Removing and installing steering wheel 20.1.95
STEERING 763.000 in MODEL 638 except CODE (SA5) Driver airbag
1 Impact absorber
2 Steering wheel
3 Nut
N46.10-2193-05
e d Removing, installing
1 Remove Mercedes emblem from steering
wheel
2 Turn steering wheel (2) to center position i The wheels must be in the straightahead and lock steering lock in position position
3 Unscrew nut (3) i Installation: Only tighten nut securely
after road test
n *BA46.10-N-1001-05A
4 Pull off steering wheel (2)
5 Install in reverse order
6 Carry out road test i Installation: Check position of steering
wheel
n Steering wheel, jacket tube, steering shaft
Number Designation Steering
763.000 in
model
638
BA46.10-N-1001-05A Nut, steering wheel to steering shaft Nm 70
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AR83.20-S-1835A Removing and installing switch unit for heater/ventilation 3.4.95
MODEL 638.0 /1 /2 (except 638.094 /194 /294)
1 Air distribution switch traction rod
2 Clamps
3 Air distribution switch traction rod
M40m45.1 Control module plug-in
connection
M40m45.2 Control module plug-in
connection
S24 Switch unit
S83.20-2003-06
e d Removal, installation
1 Remove cover on center of instrument panel AR68.10-S-3430A
2 Remove clamps (2)
3 Unhook air distribution switch control rods i Installation: Check that air gates open (1,3) and close completely.
4 Disconnect plug-in connections (M40m45.1,
M40m45.2) and remove switch unit (S24)
5 Install in reverse order
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AR83.10-S-2059A Removing and installing switchover valve for fresh air flap and recirculated air 15.2.95
flap
MODEL 638.0 /1 /2
1 Vacuum pipe
2 Screw
3 Vacuum pipe
M40y77.1 Plug-in connection for
switchover valve
M40y77 Switchover valve
S83.10-2000-06
e d Removal, installation
1 Disconnect vacuum line (1) and (3) i Check state of vacuum line (1)and (3),
replacing it if necessary
2 Disconnect the switchover valve plug-in
connection (M40y77.1)
3 Unscrew screw (2)
4 Remove switchover valve (M40y77)
5 Install in reverse order
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AR68.10-S-1111A Removing and installing the instrument panel 10.4.96
MODEL 638
S68.10-2007-09
1 Bolt 10 Bolt A25.1 Plug connection of radio
2 Bolt 11 Bolt frequency locking control
3 Supporting strut 12 Vacuum line module
4 Bolt A47.1 Transponder plug connection
A16 Bulb failure monitoring 5 Bolt M40y77 Recirculated air flap valve
module6 Bolt S80 Parking brake switch
A16.1 Plug connection of bulb 7 Nut S80.1 Plug connection of parking
failure monitoring module8 Bolt brake switch
A25 Radio frequency locking 9 Spring
control module
e d Removing, installing
i All the cable straps which are separated when removing, must be replaced when
installing
1 Remove instrument panel AR68.10-S-1000A
2 Separate plug connection of exterior bulb
failure monitoring module (A16.1)
3 Remove exterior bulb failure monitoring
module (A16)
4 Separate plug connection of radio frequency
locking control module (A25.1)
5 Unclip radio frequency locking control module
(A25)
6 Separate plug connection of transponder
(A47.1)
7 Detach vacuum line (12) from recirculating
air flap valve (M40y77)
8 Separate plug connection (S80.1) of parking
brake switch (S80)
9 Unscrew bolts (1)
10 Unscrew bolt (2) of supporting strut (3)
11 Unscrew bolts (5)
12 Unscrew bolt (4)
13 Unscrew bolt (11)
14 Unscrew bolts (6) i Leave shift lever bracket with attached
shift cables hanging.
n *BA27.60-N-1001-05A
15 Unscrew bolts (8) n *BA46.10-N-1002-05A
16 Unscrew nuts (7) i Pull steering column down.
n *BA46.10-N-1002-05A Copyright Daimler AG 11/10/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
17 Detach spring (9) at brake pedal
18 Unscrew bolts (10) and take out instrument p Ensure that no electric cables are panel carrier damaged.
19 Install in the reverse order
n Shift mechanism, control
Number Designation Model
638
BA27.60-N-1001-05A Shift bracket ot waistrail carrier Nm 20
n Steering column, steering column tube, steering shaft
Number Designation Steering Steering
763.000 in 763.000 in
model 638 model
638 with
airbag
BA46.10-N-1002-05A Steering column tube of steering shaft to Nm 15 15
crosstube of instrument panel
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AR83.10-S-8915A Removing and installing vacuum actuator for fresh air/recirculated air flap 6.2.95
MODEL 638
1 Vacuum actuator
2 Screw
3 Fresh air/recirculated air flap lever
4 Rod
5 Vacuum line
S83.20-2006-06
e d Removal, installation
1 Remove instrument panel support AR68.10-S-1111A
2 Take vacuum line (5) out
3 Unscrew screws (2)
4 Unhook rod (4) of the fresh air/recirculated
air flap
5 Remove vacuum actuator (1)
6 Install in reverse order
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AR83.25-S-1155A Removing and installing water bypass valve 10.4.96
MODEL 638.0 /1 /2
1 Hose
2 Hose
3 Rubber guide
4 Support
5 Vibration damper
6 Nut
7 Hose
8 Air filter box lid
Y37 Water bypass valve/Air
conditioning
Y37.1 Water bypass valve plug-in
connection/Air conditioning
S83.20-2001-06
e d Removal, installation
Danger of severe burns to skin and eyes Open cooling system only when coolant AS20.00-Z-0001-01Aa Danger! from hot coolant spewing out. Coolant is temperature is below 90 °C. Open cover
toxic when swallowed slowly and reduce pressure. Do not fill
beverage containers with coolant. Wear
protective gloves, protective clothing and
protective goggles.
1 Eliminate the pressure from the coolant
circuit
2 Remove the air filter box lid (8) i To facilitate removal
3 Drain the coolant AP20.00-D-2080A
4 Remove hoses (1, 2, 7) from the water l *000589543700 bypass (Y37) abbauen
5 Disconnect the water bypass valve plug-in
connection (Y37.1)
6 Unscrew nut (6), removing the water bypass
valve (Y37) with the support (4)
7 Remove the water bypass valve (Y37) from i Check the wear of the vibration damper support (4) (5) and the rubber guide (3), replacing them
if required.
8 Reinstall in opposite order
000 589 54 37 00
Clip
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AR82.00-S-9999A Removing, replacing and installing cigarette lighter 17.1.95
MODEL 638
1 Bolt
2 Lamp base
3 Ashtray bottom section
4 Ashtray top section
5 Plug-in wiring connection
E17 Cigar lighter
S82.00-2501-06
e d Removing, installing
1 Unscrew screws (1) p Do not damage center console.
i Screws are only accessible after opening
ashtray.
2 Unclip ashtray at side and pull out upward
3 Unclip ashtray bottom section (3) from i Carefully bend lugs outward at marked ashtray top section (4) point.For this purpose do not open ashtray
bottom section completely up to arresting
point.
4 Disconnect electrical connector (5)
5 Remove lamp base (2) i Carefully pry out lamp base (2) by
pressing from side.
6 Remove cigarette lighter (E17)
7 Install in the reverse order
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