AF83.10-S-1002AG Noise at recirculated air flap MODEL 638.

### ## up to 023549 with CODE (H81) Ventilation system with filter

4.11.96

Damage code 83 033 16 83 033 41

Cause Recirculated air flap malfunction

Remedy 1 Remove complete instrument panel 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

Control linkage

S83.10-1012-01

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AR83.25-S-1200A MODEL 638.0 /1 /2

Removing and installing blower motor

6.2.95

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

ed 1 2 3 4 5

Removal, installation Remove footwell cover on driver's side Remove fog lamp switch Unscrew screws (4) for bracket (5) on instrument panel bracket (6) i Unhook footwell cover on one side AR54.25-S-3251A i Push insert (3) up until screws (4) are visible.

6 7 8 9

Remove bracket (5) Cut through cable strap on protective cap for i Installation: Replace cable strap. electric connectors on instrument panel bracket (6) Disconnect blower motor connector (M40m45.1) Unscrew screws (1) Remove blower motor (M40m45) from heater housing Reinstall in opposite order

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AR83.10-S-4503A MODEL 638

1 2 3

Removing and installing center air outlet

6.2.95

Screw Centre air outlet Instrument panel centre cover

S68.10-2002-11

ed 1 2 3

Removal, installation Remove instrument panel centre cover (3) Unscrew screw (1) and remove centre air outlet (2) Install in reverse order AR68.10-S-3430A

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AR68.20-S-2000A Removing and installing center console 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 2 Center console Screws

20.5.99

S68.20-2500-05

ed 1 2 3

Removing and installing Unscrew screws (2) Unscrew plastic nut (arrow) on right and left side 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

Install in the reverse order

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AR68.10-S-3430A MODEL 638

Removing and installing center cover on instrument panel

6.2.95

S68.10-2000-09

Illustrated on model 638 except models 638.094/194/294 1 2 3 Screws Knob Nut 4 Center cover on instrument panel 5 Interior temperature sensor cover B34 Interior temperature sensor B34.1 Interior temperature sensor connection SX Type of switch used SX.1 Type of switch connector used

ed p 1

Removal, installation Notes on battery Disconnect ground lead from battery All models i Installation - Set clock. See@ Owner's manual. - Code radio. AH54.10-P-0001-01A AR54.10-S-0005A

2 3.1 4.1 5.1

Remove radio Pull off knobs (2) Unscrew nuts (3) Remove selector lever cover

i Remove with mounting frame. Except models 638.094/194/294 p Do not damage parts. i Except models 638.094/194/294 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

AR82.60-S-7502A

6 7 8

9.1

Unscrew screws (1) Remove center cover on instrument panel (4) p Carefully unclip to prevent damaging retaining catches (danger of breaking) 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 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 STEERING 763.000 in MODEL 638 with CODE (SA5) Driver airbag
1 2 4 Outer steering column cover Inner steering column cover Plastic cable pouch

7.6.01

S54.18-4007-03

1 2 3

Outer steering column cover Inner steering column cover 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

ed

Removing, installing

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a Danger!

Risk of injury when carrying out test or repair work on airbag or emergency tensioning retractor units Remove steering wheel Detach outer steering column cover (1) Unscrew retaining bolts (3) Detach inner steering column cover (2) Detach paneling under left side of instrument panel Cut through cable straps on plastic cable pouch (4) and guide all electrical connectors down and out of the plastic cable pouch (4)

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 C. Interrupt power supply when working on such units. i Wheels must be in straight-ahead position.

AS91.00-Z-0001-01A

1 2 3 4 5 6

AR46.10-S-0100B

i Model 638.2 only i The plastic cable pouch (4) remains fastened to the transverse rod behind the instrument panel. i Installation: Replace cable strap.

7 8

10

Unplug connectors (X113 and X125) from wiring harness (5) of contact spiral (R5) 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. 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 antirotation device when the contact spiral is removed. 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 MODEL 638.0 /1 /2

1 2 3 4 Clamp Control cable Clamp Control cable

Removing and installing control cables from heater/ventilation control unit

10.4.96

S83.10-2005-06

ed 1 2 3 4 5 6

Removal, installation Remove instrument panel i Only to remove control cable (2) AR68.10-S-1000A Unclip clips and unhook control cables (2) i Remove control unit for heater/ventilation. AR83.20-S-1835A and (4) from heater/ventilation control unit Remove clamp (1) and unhook control cable (2) from defrosting diffuser. Remove clamp (3) and unhook control cable (4) from gate for the interior air diffuser. Remove control cables (2) and (4) 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 MODEL 638 On the steering column

Removing and installing electrical center

21.3.95

S54.25-1001-09

1 2 3 4 5

Cover Paneling Bolt Bolt Nut

A12.1 A12.2 A12.3 A12.4 A12.5 A12.6

Electrical center (steering column switch connector) Electrical center (main power switch connector) Electrical center (frame wiring harness connector) Electrical center (frame wiring harness connector) Electrical center (frame wiring harness connector) Connector

A12 Electrical center (without steering column switch)

ed 1 2 3 4 5

Removing, installing Disconnect ground cable of battery Detach cover (1) Unscrew bolts (3) Detach paneling (2) Remove contact spiral AR54.10-S-0005A

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.

Loosen electrical center (A12) by unscrewing p Installation: Do not tilt the electrical bolt (4) and nut (5) center (A12) when tightening. n n Unplug electrical connectors from electrical center (A12) Remove electrical center (A12) Install in the reverse order

*BA54.25-N-1001-01A *BA54.25-N-1002-01A

7 8 9 n Switches Number

Designation

Model 638 Nm Nm 4 6

BA54.25-N-1001-01A BA54.25-N-1002-01A

Bolt, electrical center to steering column switch Nut, electrical center to steering column

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AR54.30-S-6015A Removing and installing instrument cluster MODEL 638 / / (except 638.094 /194 /294)
1 Plug connection of indicator lamps 2 Screws P15 P15.1 P15.2 P15.3 Instrument cluster Connector Connector Connector

27.1.95

S54.30-1004-06

ed 1 2 3 4 5 6 7.1 8.1 9 g 10

Removing, installing Unscrew screws (2) Remove left air vent Push out instrument cluster (P15) from the rear p Do not damage instrument panel and instrument cluster (P15). AR83.10-S-4740A p Do not damage instrument panel and instrument cluster (P15).

Release plug connections (P15.1, P15.2 and i Plug connections are color coded. P15.3) and pull off connections Pull off plug connections (1) together with i Pay attention to installation position of indicator lamps indicator lamps. Remove instrument cluster (P15) p Do not damage instrument panel and instrument cluster (P15). Connect adapter cable and adapter to instrument cluster (P15) Parameterize instrument cluster (P15) Install in the reverse order Inspecting Read out fault memory with HHT AD00.00-S-2000-03A i Only if instrument cluster is replaced (P15). i Only if instrument cluster is replaced (P15). AD54.30-S-2003-04A AD54.30-S-2003-06A

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AR68.10-S-1000A MODEL 638

Removing and installing instrument panel

8.2.95

S68.10-2004-09

Shown on model 638 except models 638.094/194/294 1 2 3 4 5 Screw Cover of speaker Foam rubber wedge Loudspeaker Bolt 6 7 8 9 10 Bolt (only in models 638.094/194/294) Fuse box Release lever of parking brake Bolt Cover of hood release 11 Cable of parking brake 12 Bolt 13 Bolt 14 Bolt S119 Switch off fog lamps

ed p 1

Removing, installing Notes on battery Disconnect ground cable of battery All models i Installation: - Set time. - Encode radio. AH54.10-P-0001-01A AR54.10-S-0005A

2 3

Remove steering column switch Remove instrument cluster Remove instrument cluster

i Only in model 638 except 638.094/194/294 i Only in model 638.094/194/294 i In model 638.0/1/2 except 638.294. i In model 638.294. i Only with code SA6.

AR54.25-S-2801A AR54.30-S-6015A AR54.30-S-6015B AR54.25-S-3251A AR54.25-S-3251B AR91.60-S-0680A AR82.00-S-9999A AR68.10-S-3430A AR82.62-S-7833A

4 5.1 6 N 8 9 10 11 12 13

Remove switch of fog lights (S119) Detach passenger airbag Remove ashtray Remove cover of instrument panel in middle Remove right and left speakers (4) Open glove compartment lid, unclip lighting and separate plug connection Take off covers on left and right below instrument panel Detach cable of parking brake (11) and take off release lever of parking brake (7) Unscrew bolts (9), take off cover of hood release (10) Unscrew bolts (5)

i Cable for hood release can remain installed. i Remove foam rubber wedge (3) first of all. i Installation: Ensure the foam rubber wedge (3) is correctly installed.

14 15.1

Remove screws (14) below instrument cluster Take out screw (6) of heater operating unit

i Only in model 638.094/194/294.

Page 1

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16 17 18 19 20 21

Unclip electrical system of airbag from bottom part of instrument panel Remove fuse box (7) Take out screw (13) below the ashtray Take out screw (12) behind cover of instrument panel in middle Unscrew screws (1) Pull out instrument panel

i The fuse box system remains installed.

i Screws (1) must be pressed out on both sides. 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 g 23

Install in the reverse order Inspecting Read fault memory, erase i See step 3 for this purpose.

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AR83.10-S-4740A MODEL 638.0 /1 /2

1 2 3 Left air nozzle Right air nozzle Installation wedge

Removing and installing side air outlet

20.1.95

S83.10-2007-02

S83.10-2008-02

ed 1

Removal, installation Remove air nozzles (1, 2) p Unclip air nozzles (1) and (2) at bottom with installation wedge (3) without damaging instrument panel. l *110589035900

Reinstall in opposite order

110 589 03 59 00
Installation wedge

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AR54.25-S-2801A MODEL 638

Removing and installing steering column switch

17.5.99

S54.25-1006-09

1 2 3 ed 1 p 2 3 4 5 6

Bolt Windshield wiper switch Turn signal switch

4 5 6

Bolt Upper cover Bolt

A12 Steering column switch S123 Cruise control switch

Removing, installing Disconnect ground cable of battery Notes on battery Remove steering wheel Remove electrical center Unscrew bolts (1) Unscrew bolts (4) from upper cover (5) Remove upper cover (5) i Installation: -Set time. All models Without code SA5 (driver airbag) With code SA5 (driver airbag) -Code radio. AR54.10-S-0005A AH54.10-P-0001-01A AR46.10-S-0100A AR46.10-S-0100B AR54.25-S-1382A

7.1

Unplug connector from cruise control switch (S123)

i Move turn signal switch (3) and windshield wiper switch (2) to the bottom positions to facilitate removal. Only with code MD0 (cruise control for manual transmission) or code MD9 (cruise control for automatic transmission)

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. i Only with code MD0 (cruise control for manual transmission) or code MD9 (cruise control for automatic transmission)

Unscrew bolt (6) from cruise control switch (S123)

10

Detach cruise control switch (S123) from steering column switch (A12)

i Only with code MD0 (cruise control for manual transmission) or code MD9 (cruise control for automatic transmission)

11 g 12

Install in the reverse order Checking Carry out function test

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AR46.10-S-0100A Removing and installing steering wheel STEERING 763.000 in MODEL 638 except CODE (SA5) Driver airbag
1 2 3 Impact absorber Steering wheel Nut

20.1.95

N46.10-2193-05

ed 1 2 3

Removing, installing Remove Mercedes emblem from steering wheel Turn steering wheel (2) to center position and lock steering lock in position Unscrew nut (3)

i The wheels must be in the straightahead position i Installation: Only tighten nut securely after road test n *BA46.10-N-1001-05A

4 5 6

Pull off steering wheel (2) Install in reverse order 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 Nm 70

BA46.10-N-1001-05A

Nut, steering wheel to steering shaft

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AR83.20-S-1835A Removing and installing switch unit for heater/ventilation MODEL 638.0 /1 /2 (except 638.094 /194 /294)
1 2 3 Air distribution switch traction rod Clamps Air distribution switch traction rod Control module plug-in Control module plug-in Switch unit

3.4.95

M40m45.1 connection M40m45.2 connection S24

S83.20-2003-06

ed 1 2 3 4 5

Removal, installation Remove cover on center of instrument panel Remove clamps (2) Unhook air distribution switch control rods i Installation: Check that air gates open (1,3) and close completely. Disconnect plug-in connections (M40m45.1, M40m45.2) and remove switch unit (S24) Install in reverse order AR68.10-S-3430A

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AR83.10-S-2059A MODEL
1 2 3

Removing and installing switchover valve for fresh air flap and recirculated air flap

15.2.95

638.0 /1 /2

Vacuum pipe Screw Vacuum pipe

M40y77.1 Plug-in connection for switchover valve M40y77 Switchover valve

S83.10-2000-06

ed 1 2 3 4 5

Removal, installation Disconnect vacuum line (1) and (3) Disconnect the switchover valve plug-in connection (M40y77.1) Unscrew screw (2) Remove switchover valve (M40y77) Install in reverse order i Check state of vacuum line (1)and (3), replacing it if necessary

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AR68.10-S-1111A MODEL 638

Removing and installing the instrument panel

10.4.96

S68.10-2007-09

1 2 3 4 5 6 7 8 9

Bolt Bolt Supporting strut Bolt Bolt Bolt Nut Bolt Spring

10 11 12

Bolt Bolt Vacuum line

A16 Bulb failure monitoring module A16.1 Plug connection of bulb failure monitoring module A25 Radio frequency locking control module Removing, installing All the cable straps which are separated when removing, must be replaced when installing Remove instrument panel Separate plug connection of exterior bulb failure monitoring module (A16.1) Remove exterior bulb failure monitoring module (A16) Separate plug connection of radio frequency locking control module (A25.1) Unclip radio frequency locking control module (A25) Separate plug connection of transponder (A47.1) Detach vacuum line (12) from recirculating air flap valve (M40y77) Separate plug connection (S80.1) of parking brake switch (S80) Unscrew bolts (1) Unscrew bolt (2) of supporting strut (3) Unscrew bolts (5) Unscrew bolt (4) Unscrew bolt (11) Unscrew bolts (6)

A25.1 Plug connection of radio frequency locking control module A47.1 Transponder plug connection M40y77 Recirculated air flap valve S80 Parking brake switch S80.1 Plug connection of parking brake switch

ed i

1 2 3 4 5 6 7 8 9 10 11 12 13 14

AR68.10-S-1000A

i Leave shift lever bracket with attached shift cables hanging. n *BA27.60-N-1001-05A *BA46.10-N-1002-05A *BA46.10-N-1002-05A n i Pull steering column down. n
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15 16

Unscrew bolts (8) Unscrew nuts (7)

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17 18 19

Detach spring (9) at brake pedal Unscrew bolts (10) and take out instrument panel carrier Install in the reverse order

p Ensure that no electric cables are damaged.

n Shift mechanism, control Number Designation Model 638 Nm 20

BA27.60-N-1001-05A

Shift bracket ot waistrail carrier

n Steering column, steering column tube, steering shaft Number Designation Steering Steering 763.000 in 763.000 in model 638 model 638 with airbag Nm 15 15

BA46.10-N-1002-05A

Steering column tube of steering shaft to crosstube of instrument panel

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AR83.10-S-8915A MODEL 638

1 2 3 4 5

Removing and installing vacuum actuator for fresh air/recirculated air flap

6.2.95

Vacuum actuator Screw Fresh air/recirculated air flap lever Rod Vacuum line

S83.20-2006-06

ed 1 2 3 4 5 6

Removal, installation Remove instrument panel support Take vacuum line (5) out Unscrew screws (2) Unhook rod (4) of the fresh air/recirculated air flap Remove vacuum actuator (1) Install in reverse order AR68.10-S-1111A

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AR83.25-S-1155A MODEL 638.0 /1 /2

1 2 3 4 5 6 7 8 Hose Hose Rubber guide Support Vibration damper Nut Hose Air filter box lid

Removing and installing water bypass valve

10.4.96

Y37 Water bypass valve/Air conditioning Y37.1 Water bypass valve plug-in connection/Air conditioning

S83.20-2001-06

ed a Danger!

Removal, installation Danger of severe burns to skin and eyes from hot coolant spewing out. Coolant is toxic when swallowed Open cooling system only when coolant temperature is below 90 C. Open cover slowly and reduce pressure. Do not fill beverage containers with coolant. Wear protective gloves, protective clothing and protective goggles. AS20.00-Z-0001-01A

1 2 3 4 5 6 7

Eliminate the pressure from the coolant circuit Remove the air filter box lid (8)

i To facilitate removal Drain the coolant Remove hoses (1, 2, 7) from the water l bypass (Y37) abbauen Disconnect the water bypass valve plug-in connection (Y37.1) Unscrew nut (6), removing the water bypass valve (Y37) with the support (4) 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. Reinstall in opposite order

AP20.00-D-2080A *000589543700

000 589 54 37 00
Clip

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AR82.00-S-9999A MODEL 638

1 2 3 4 5

Removing, replacing and installing cigarette lighter

17.1.95

Bolt Lamp base Ashtray bottom section Ashtray top section Plug-in wiring connection

E17 Cigar lighter

S82.00-2501-06

ed 1

Removing, installing Unscrew screws (1) p Do not damage center console. i Screws are only accessible after opening ashtray. i Carefully bend lugs outward at marked point.For this purpose do not open ashtray bottom section completely up to arresting point. i Carefully pry out lamp base (2) by pressing from side.

2 3

Unclip ashtray at side and pull out upward Unclip ashtray bottom section (3) from ashtray top section (4)

4 5 6 7

Disconnect electrical connector (5) Remove lamp base (2) Remove cigarette lighter (E17) Install in the reverse order

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