Positioning:
The Mercedes-Benz A-Class (W168) was a pioneering compact premium hatchback, targeting a younger demographic and offering innovative design (sandwich floor concept) and Mercedes-Benz quality in a smaller package.
Competitors:
Competed against established compact cars like the Volkswagen Golf, Ford Focus, Opel Astra, and BMW 1 Series (though the latter arrived later).
Innovations:
Sandwich floor design for enhanced safety and interior space, compact dimensions with practical interior, distinctive styling.
Value:
This manual provides technicians and owners with the specific, in-depth knowledge required to accurately maintain and repair the W168 A-Class, mirroring dealership-level expertise and avoiding generic automotive advice.
Primary Coverage:
All W168 A-Class Models (1997-2005)
Repair Scope:
A-Z (Comprehensive Repairs)
Estimated Page Count:
Varies by specific publication, typically 500-1500 pages for comprehensive service manuals.
Type:
Service and Repair Manual
Language:
English (Standard for technical manuals of this nature, though original may vary).
Format:
Likely a digitized format (PDF) for modern sales, potentially a physical book.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine management (ECU diagnostics), cooling system, lubrication system.
Transmission:
Manual and Automatic Transmission (including Automated Manual Transmission - 'Softtouch' and 'Soft-touch PLUS' in W168 context), clutch, driveshafts, differentials.
Chassis:
Suspension (front and rear independent), steering system, braking system (ABS, EBD), wheels, tires.
Electrical:
12V electrical system, battery, alternator, starter motor, lighting (headlights, taillights, interior), power windows, central locking, wipers, horn, fuse box diagrams, wiring schematics.
Body:
Body panel removal/installation, interior trim, doors, windows, seats, HVAC (heating, ventilation, and air conditioning) system, safety systems (airbags, seatbelts).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad/disc service, belt replacement.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues, error code interpretation.
Repair:
Engine component overhaul (cylinder head, pistons, crankshaft), transmission overhaul, suspension component replacement, brake caliper rebuilding, electrical component repair, bodywork repairs.
Diagnostics:
OBD-II (On-Board Diagnostics) troubleshooting, sensor testing, actuator testing, ECU parameter reading.
Depth:
Expert level, suitable for professional technicians and advanced DIYers. Covers diagnostic procedures, component specifications, tolerances, and overhaul instructions.
Engine Families:
M166 (petrol), OM668 (diesel)
Petrol Engines Offered:
A140 (1.4L M166 E14), A160 (1.6L M166 E16), A190 (1.9L M166 E19), A210 Evolution (2.1L M166 E21).
Diesel Engines Offered:
A160 CDI (1.7L OM668 DE17 LA), A170 CDI (1.7L OM668 DE17 LA), A170 CDI Long (1.7L OM668 DE17 LA).
Typical Horsepower Range:
60 kW (82 PS) to 103 kW (140 PS) depending on engine variant.
Typical Torque Range:
135 Nm to 210 Nm depending on engine variant.
Petrol Fuel Delivery:
Electronic Fuel Injection (EFI), multi-point injection (MPI).
Diesel Fuel Delivery:
Direct injection (DI) with turbocharging and intercooling for CDI variants.
ECU Systems:
ME-SFI (Motor Electronics - Sequential Fuel Injection) for petrol, CDI control unit for diesel.
Standard Transmission:
5-speed manual transmission.
Optional Transmission:
Automated Manual Transmission (AMT) branded as 'Soft-touch' or 'Soft-touch PLUS'.
Amt Description:
Hydraulically actuated clutch and gear shifting controlled by an electronic unit, providing automatic operation without a torque converter.
Manual Transmission Fluid:
MB 235.10 (GL-4) or similar specification (check specific model variant).
Automatic Transmission Fluid:
Refer to specific 'Soft-touch' system hydraulic fluid specifications in the manual.
Length:
Approx. 3626 mm (standard wheelbase), 3776 mm (Long version).
Curb Weight:
Varies by model, typically 1150 kg to 1350 kg.
Gross Vehicle Weight:
Varies by model, typically 1700 kg to 1850 kg.
Euro Ncap Rating:
Initially 3 stars (1998), later improved. The 'sandwich' floor concept contributed to high occupant protection in frontal impacts.
Active Safety:
Optional ABS (Anti-lock Braking System), optional ESP (Electronic Stability Program) on some later models.
Passive Safety:
Advanced rigid safety cell, front airbags, side airbags (optional), seatbelt pre-tensioners, impact-absorbing steering column.
Infotainment Systems:
Basic radio/cassette or CD players, optional navigation systems on later models. Limited by the era of production.
Driver Assistance Features:
Optional parking sensors (rear), cruise control on some variants. Primarily focused on core driving dynamics and safety.
Connectivity Options:
Limited to basic audio inputs and phone preparation on some models. No advanced smartphone integration or Bluetooth as standard.
Oil Change Interval:
Typically every 15,000 km or 12 months, whichever comes first (dependent on service indicator system 'Assyst'). Diesel models may have different intervals.
Major Service Intervals:
Refer to manual for scheduled checks at intervals like 30,000 km, 60,000 km etc. (e.g., spark plug replacement, brake fluid change).
Engine Oil Specification:
MB 229.1 or MB 229.3 (e.g., Mobil 1 0W-40, Shell Helix Ultra 5W-40). Always verify with the specific engine type and manual.
Coolant Specification:
MB-Approval 325.0 / 325.2 (Ethylene Glycol based, silicate-free concentrate).
Brake Fluid Specification:
DOT 4 (e.g., MB 331.0).
Common W168 Issues:
Wear on front suspension components (ball joints, bushings), potential issues with the 'Soft-touch' automated manual transmission (actuator, hydraulic system), exhaust manifold cracks (especially on early petrol engines), occasional electrical gremlins, corrosion on certain body panels.
Diesel Specific Issues:
Turbocharger wear, injector seal leaks, glow plug failures on OM668 diesel engines.
Heritage Context:
Mercedes-Benz, a brand synonymous with luxury, engineering, and safety, sought to expand its market reach with the A-Class.
Generation Details:
The W168 marked Mercedes-Benz's first foray into the compact hatchback segment. It was designed by Mercedes-Benz and produced in Rastatt, Germany. A facelift occurred in 2001.
Production Period:
October 1997 - July 2004.
Production Location:
Rastatt, Germany; Kecskemét, Hungary (under license).
Notable Awards:
While not a recipient of numerous specific awards, the W168 was recognized for its innovative safety design, particularly the sandwich floor concept, which contributed to its Euro NCAP performance.
Safety Recognition:
Its safety structure was a key selling point, and the manual details the procedures to maintain these safety systems.
