You are on page 1of 22

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

1

Control linkage

S83.10-1012-01

Copyright Daimler AG 11/10/11 G/06/08. This WIS printout will not be recorded by the update service.

Page 1

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

Copyright Daimler AG 11/7/11 G/06/08. This WIS printout will not be recorded by the update service.

Page 1

installation Remove instrument panel centre cover (3) Unscrew screw (1) and remove centre air outlet (2) Install in reverse order AR68.AR83. This WIS printout will not be recorded by the update service.10-2002-11 ed 1 2 3 Removal.95 Screw Centre air outlet Instrument panel centre cover S68. Page 1 .10-S-4503A MODEL 638 1 2 3 Removing and installing center air outlet 6.10-S-3430A Copyright Daimler AG 11/10/11 G/06/08.2.

20-S-2000A Removing and installing center console MODEL 638.99 S68. i To facilitate removal pull center console (1) apart slightly 4 Install in the reverse order Copyright Daimler AG 11/10/11 G/06/08.5.2 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 20.20-2500-05 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.AR68. Page 1 . This WIS printout will not be recorded by the update service.

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 Type of switch connector used ed p 1 Removal.10-2000-09 Illustrated on model 638 except models 638.094/194/294 i Only on model 638. See@ Owner's manual.Code radio. The switch designation (SX) and (SX. 10 Install in opposite order pInstallation : In model 638 except models 638.10-S-0005A 2 3.1) to associated (SX) switches (SX) (arows).094/194/294 pay attention to illuminated pin on heater/ventilation switch unit (danger of breaking) Page 1 Copyright Daimler AG 11/10/11 G/06/08.1) from switch i Mark connectors (SX. AH54.094/194/294. i 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) stand for all other switch and connection designations Disconnect temperature sensor connector i Only with code H06 (air conditioning) in (B34. i It is not necessary to remove the interior temperature sensor cover (5).2 without code G40 (automatic transmission) and model 638.1) model 638 except models 638.094/194/294 p Do not damage parts.094/194 without code G40 (automatic transmission) i Separate cables straps Pull selector lever cover up and off AR82.1 4.2.10-S-3430A MODEL 638 Removing and installing center cover on instrument panel 6.10-P-0001-01A AR54. Except models 638. .1 5. installation Notes on battery Disconnect ground lead from battery All models i Installation .95 S68.1 Remove radio Pull off knobs (2) Unscrew nuts (3) Remove selector lever cover i Remove with mounting frame.Set clock. This WIS printout will not be recorded by the update service.60-S-7502A 6 7 8 9.1 Interior temperature sensor connection SX Type of switch used SX. .AR68.

6. installing Copyright Daimler AG 11/10/11 G/06/08.01 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 S46.25-1003-01 S54. Page 1 . This WIS printout will not be recorded by the update service.10-S-0200A Removing and installing contact spiral STEERING 763.18-4007-03 1 2 3 Outer steering column cover Inner steering column cover Retaining bolt S54.AR46.10-4001-06 ed Removing.000 in MODEL 638 with CODE (SA5) Driver airbag 1 2 4 Outer steering column cover Inner steering column cover Plastic cable pouch 7.

7 8 9 10 Unplug connectors (X113 and X125) from wiring harness (5) of contact spiral (R5) Detach adhesive tapes. Carefully remove contact spiral (R5) from p The contact spiral (R5) must never be steering shaft opened under any circumstances.10-S-0200-01A 11 Install in the reverse order Copyright Daimler AG 11/10/11 G/06/08.00-Z-0001-01A 1 2 3 4 5 6 AR46. i Installation: Replace cable strap. 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.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. 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. do not expose to temperatures greater than 100 °C.2 only i The plastic cable pouch (4) remains fastened to the transverse rod behind the instrument panel.10-S-0100B i Model 638. The retaining bolts (6) also act as an antirotation device when the contact spiral is removed. i Wheels must be in straight-ahead position. AS91. Refer to: @ Adjusting center position of contact spiral AR46. the center position must be reset. p If the contact spiral (R5) was twisted by unscrewing the retaining bolts (6) all the way. This WIS printout will not be recorded by the update service. vicinity of electrical center i Replace cable straps. Interrupt power supply when working on such units. Page 2 .

96 S83.10-2005-06 ed 1 2 3 4 5 6 Removal.10-S-1000A Unclip clips and unhook control cables (2) i Remove control unit for heater/ventilation. Remove clamp (3) and unhook control cable (4) from gate for the interior air diffuser.20-S-1835A and (4) from heater/ventilation control unit Remove clamp (1) and unhook control cable (2) from defrosting diffuser. Page 1 .0 /1 /2 1 2 3 4 Clamp Control cable Clamp Control cable Removing and installing control cables from heater/ventilation control unit 10. This WIS printout will not be recorded by the update service. 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.AR83. Copyright Daimler AG 11/10/11 G/06/08. installation Remove instrument panel i Only to remove control cable (2) AR68. AR83.10-S-2500A MODEL 638.4.

5 A12.25-N-1001-01A *BA54.4 A12.25-1001-09 1 2 3 4 5 Cover Paneling Bolt Bolt Nut A12. n n Unplug electrical connectors from electrical center (A12) Remove electrical center (A12) Install in the reverse order *BA54.10-S-0200A p Do not unscrew the bolts all the way.10-S-0005A Only with code SA5 (driver airbag) AR46.6 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.3. electrical center to steering column switch Nut.25-N-1001-01A BA54. 6 Loosen electrical center (A12) by unscrewing p Installation: Do not tilt the electrical bolt (4) and nut (5) center (A12) when tightening. The contact spiral must never be opened under any circumstances.25-S-1382A MODEL 638 On the steering column Removing and installing electrical center 21.AR54.2 A12. This WIS printout will not be recorded by the update service. The bolts also act as an anti-rotation device.3 A12.95 S54.25-N-1002-01A Bolt.25-N-1002-01A 7 8 9 n Switches Number Designation Model 638 Nm Nm 4 6 BA54. electrical center to steering column Copyright Daimler AG 11/10/11 G/06/08. Page 1 . installing Disconnect ground cable of battery Detach cover (1) Unscrew bolts (3) Detach paneling (2) Remove contact spiral AR54.1 A12.

i Only if instrument cluster is replaced (P15).094 /194 /294) 1 Plug connection of indicator lamps 2 Screws P15 P15. P15.1. Page 1 .1 9 g 10 Removing.3 Instrument cluster Connector Connector Connector 27.95 S54.1 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 AD00.30-1004-06 ed 1 2 3 4 5 6 7.00-S-2000-03A i Only if instrument cluster is replaced (P15).10-S-4740A p Do not damage instrument panel and instrument cluster (P15). AD54. Release plug connections (P15.2 P15.1 8.2 and i Plug connections are color coded.1. 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). This WIS printout will not be recorded by the update service.30-S-6015A Removing and installing instrument cluster MODEL 638 / / (except 638.3) and pull off connections Pull off plug connections (1) together with i Pay attention to installation position of indicator lamps indicator lamps. AR83.30-S-2003-06A Copyright Daimler AG 11/10/11 G/06/08.30-S-2003-04A AD54. Remove instrument cluster (P15) p Do not damage instrument panel and instrument cluster (P15). P15.AR54.

AH54. Page 1 Copyright Daimler AG 11/10/11 G/06/08.1 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.1 Remove screws (14) below instrument cluster Take out screw (6) of heater operating unit i Only in model 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. i Only with code SA6.10-S-1000A MODEL 638 Removing and installing instrument panel 8.62-S-7833A 4 5. i In model 638.294.094/194/294.Encode radio. . AR54.0/1/2 except 638.95 S68.25-S-3251B AR91.60-S-0680A AR82.094/194/294 1 2 3 4 5 Screw Cover of speaker Foam rubber wedge Loudspeaker Bolt 6 7 8 9 10 Bolt (only in models 638.2.25-S-3251A AR54. 14 15. This WIS printout will not be recorded by the update service.00-S-9999A AR68.10-2004-09 Shown on model 638 except models 638.Set time.094/194/294 i Only in model 638.30-S-6015B AR54. i Remove foam rubber wedge (3) first of all. installing Notes on battery Disconnect ground cable of battery All models i Installation: .10-P-0001-01A AR54.AR68. .25-S-2801A AR54.094/194/294 i In model 638. i Installation: Ensure the foam rubber wedge (3) is correctly installed.10-S-0005A 2 3 Remove steering column switch Remove instrument cluster Remove instrument cluster i Only in model 638 except 638.30-S-6015A AR54. 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.10-S-3430A AR82.294.

i Screws (1) must be pressed out on both sides. i Installation: The guide pins must engage in the recesses (arrows). p Pull out instrument panel carefully. Page 2 . Ensure that no electric cables are damaged. 22 g 23 Install in the reverse order Inspecting Read fault memory.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. This WIS printout will not be recorded by the update service. erase i See step 3 for this purpose. Copyright Daimler AG 11/10/11 G/06/08.

10-S-4740A MODEL 638. Page 1 .1. l *110589035900 2 Reinstall in opposite order 110 589 03 59 00 Installation wedge Copyright Daimler AG 11/10/11 G/06/08.10-2008-02 ed 1 Removal.10-2007-02 S83.0 /1 /2 1 2 3 Left air nozzle Right air nozzle Installation wedge Removing and installing side air outlet 20. installation Remove air nozzles (1.95 S83. This WIS printout will not be recorded by the update service.AR83. 2) p Unclip air nozzles (1) and (2) at bottom with installation wedge (3) without damaging instrument panel.

All models Without code SA5 (driver airbag) With code SA5 (driver airbag) -Code radio.25-S-2801A MODEL 638 Removing and installing steering column switch 17. Only with code MD0 (cruise control for 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. 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. AR54.1 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.5.25-S-1382A 7. i Only with code MD0 (cruise control for manual transmission) or code MD9 (cruise control for automatic transmission) 9 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 Copyright Daimler AG 11/10/11 G/06/08.10-S-0100B AR54.99 S54. Page 1 .10-P-0001-01A AR46.10-S-0005A AH54.10-S-0100A AR46.AR54.25-1006-09 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. This WIS printout will not be recorded by the update service.

Page 1 .10-N-1001-05A Nut. 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 *BA46.000 in model 638 Nm 70 BA46. jacket tube.AR46. This WIS printout will not be recorded by the update service.95 N46. steering wheel to steering shaft Copyright Daimler AG 11/10/11 G/06/08.10-2193-05 ed 1 2 3 Removing.000 in MODEL 638 except CODE (SA5) Driver airbag 1 2 3 Impact absorber Steering wheel Nut 20.10-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. steering shaft Number Designation Steering 763.10-S-0100A Removing and installing steering wheel STEERING 763.1.

Page 1 .1 connection M40m45.2 connection S24 S83.2) and remove switch unit (S24) Install in reverse order AR68.10-S-3430A Copyright Daimler AG 11/10/11 G/06/08.0 /1 /2 (except 638. Disconnect plug-in connections (M40m45.AR83.1. 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. This WIS printout will not be recorded by the update service.20-S-1835A Removing and installing switch unit for heater/ventilation MODEL 638.95 M40m45. M40m45.4.20-2003-06 ed 1 2 3 4 5 Removal.3) and close completely.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.

replacing it if necessary Copyright Daimler AG 11/10/11 G/06/08. installation Disconnect vacuum line (1) and (3) Disconnect the switchover valve plug-in connection (M40y77.AR83.2. Page 1 . This WIS printout will not be recorded by the update service.10-S-2059A MODEL 1 2 3 Removing and installing switchover valve for fresh air flap and recirculated air flap 15.0 /1 /2 Vacuum pipe Screw Vacuum pipe M40y77.10-2000-06 ed 1 2 3 4 5 Removal.1 Plug-in connection for switchover valve M40y77 Switchover valve S83.1) Unscrew screw (2) Remove switchover valve (M40y77) Install in reverse order i Check state of vacuum line (1)and (3).95 638.

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 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. n *BA27. installing All the cable straps which are separated when removing.96 S68.10-S-1111A MODEL 638 Removing and installing the instrument panel 10.AR68.1 Plug connection of bulb failure monitoring module A25 Radio frequency locking control module Removing.4.1) 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) Detach vacuum line (12) from recirculating air flap valve (M40y77) Separate plug connection (S80. .1) Unclip radio frequency locking control module (A25) Separate plug connection of transponder (A47.1 Plug connection of radio frequency locking control module A47.60-N-1001-05A *BA46. n Page 1 15 16 Unscrew bolts (8) Unscrew nuts (7) Copyright Daimler AG 11/10/11 G/06/08. must be replaced when installing Remove instrument panel Separate plug connection of exterior bulb failure monitoring module (A16.10-S-1000A i Leave shift lever bracket with attached shift cables hanging.1) Remove exterior bulb failure monitoring module (A16) Separate plug connection of radio frequency locking control module (A25. This WIS printout will not be recorded by the update service.10-N-1002-05A n i Pull steering column down.10-N-1002-05A *BA46.

steering shaft Number Designation Steering Steering 763.10-N-1002-05A Steering column tube of steering shaft to crosstube of instrument panel Copyright Daimler AG 11/10/11 G/06/08. control Number Designation Model 638 Nm 20 BA27.000 in model 638 model 638 with airbag Nm 15 15 BA46. This WIS printout will not be recorded by the update service.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.000 in 763. n Shift mechanism. steering column tube. Page 2 .60-N-1001-05A Shift bracket ot waistrail carrier n Steering column.

This WIS printout will not be recorded by the update service.95 Vacuum actuator Screw Fresh air/recirculated air flap lever Rod Vacuum line S83.2. Page 1 .AR83.20-2006-06 ed 1 2 3 4 5 6 Removal.10-S-1111A Copyright Daimler AG 11/10/11 G/06/08.10-S-8915A MODEL 638 1 2 3 4 5 Removing and installing vacuum actuator for fresh air/recirculated air flap 6. 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.

Page 1 .1 Water bypass valve plug-in connection/Air conditioning S83.AR83. 7) from the water l bypass (Y37) abbauen Disconnect the water bypass valve plug-in connection (Y37. 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). 2. Coolant is toxic when swallowed Open cooling system only when coolant temperature is below 90 °C. Wear protective gloves. installation Danger of severe burns to skin and eyes from hot coolant spewing out. Do not fill beverage containers with coolant. Open cover slowly and reduce pressure.96 Y37 Water bypass valve/Air conditioning Y37. protective clothing and protective goggles.4.1) Unscrew nut (6).20-2001-06 ed a Danger! Removal. replacing them if required. 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) 8 i To facilitate removal Drain the coolant Remove hoses (1.00-D-2080A *000589543700 000 589 54 37 00 Clip Copyright Daimler AG 11/7/11 G/06/08. Reinstall in opposite order AP20.25-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. This WIS printout will not be recorded by the update service.

i Carefully pry out lamp base (2) by pressing from side.95 Bolt Lamp base Ashtray bottom section Ashtray top section Plug-in wiring connection E17 Cigar lighter S82. i Screws are only accessible after opening ashtray.00-2501-06 ed 1 Removing. Page 1 . installing Unscrew screws (1) p Do not damage center console.00-S-9999A MODEL 638 1 2 3 4 5 Removing.1. 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 Copyright Daimler AG 11/10/11 G/06/08. replacing and installing cigarette lighter 17. i Carefully bend lugs outward at marked point.AR82.For this purpose do not open ashtray bottom section completely up to arresting point. This WIS printout will not be recorded by the update service.