🏷️ Basic Information

Make:

Mercedes-Benz

Model:

A-Class (W168)

Variant Models:

A140, A160, A160 CDI, A170 CDI, A190, A210 Evolution

Production Years:

1997-2004

Chassis Code:

W168

👋 Introduction

Market Segment:

Compact/Subcompact hatchback, often positioned as a stylish and practical entry into the premium compact car segment.

Key Competitors:

Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series Compact (E36/5).

Unique Selling Points:

Sandwich concept platform offering excellent interior space and safety benefits (lower center of gravity), distinctive styling, Mercedes-Benz build quality and brand prestige.

Purpose:

To provide comprehensive factory-level repair and maintenance information for the Mercedes-Benz W168 A-Class, enabling accurate diagnostics, repairs, and servicing.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Fuel System, Exhaust System, Electrical System (including ECUs, wiring diagrams, lighting, instrumentation), Bodywork, Interior Trim, Safety Systems (ABS, ESP, Airbags), Diagnostic Procedures, Troubleshooting Guides

Estimated Page Count:

2000+

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul procedures for M166 petrol and OM668 diesel engines, including cylinder head, pistons, crankshaft, timing, lubrication, cooling systems.

Engine Management:

Detailed information on engine control units (ECU), fuel injection systems (petrol and diesel common rail), ignition systems, emissions control, and sensor data interpretation.

Transmission Manual:

Repair and overhaul for the manual gearbox, clutch system, shift mechanisms.

Transmission Automatic:

Repair and overhaul for the automatic transmission (e.g., 5G-Tronic for some variants), including valve body, torque converter, electronic control.

Drivetrain:

Front-wheel drive system, driveshafts, CV joints, differential.

Suspension:

Front McPherson strut suspension, rear semi-independent torsion beam, component replacement, alignment specifications.

Steering:

Power steering system, steering column, steering gear, rack and pinion maintenance and repair.

Brakes:

Front and rear disc brakes, ABS system components, brake fluid specifications, bleeding procedures, parking brake.

HVAC:

Air conditioning system, heater core, blower motor, climate control unit, refrigerant handling and service.

Electrical:

Comprehensive wiring diagrams for all circuits, battery, charging system (alternator, starter), lighting, interior and exterior electrics, fuses and relays.

Bodywork:

Body panel removal and installation, door mechanisms, tailgate, bumpers, interior trim, corrosion protection.

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, ESP (Electronic Stability Program) components and calibration.

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and top-ups, belt inspections and replacement.

Diagnostics Troubleshooting:

Systematic diagnostic procedures for common and rare faults, fault code interpretation (OBD-II), symptom-based troubleshooting.

Repair Overhaul:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for virtually all vehicle systems.

Wiring Diagrams:

Detailed, component-level electrical schematics for all vehicle systems.

Depth:

Factory-level detail suitable for professional technicians and advanced DIY enthusiasts, covering everything from routine maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, clear text and legible diagrams for easy printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Searchability:

Text-searchable PDF allowing quick access to specific topics.

Coverage Scope:

Comprehensive coverage of all model variants and engine options within the specified production years, including detailed technical data and repair procedures.

⚙️ Engine Specifications

A140:

M166 E14 (1.4L Inline-4), ~82 HP

A160:

M166 E16 (1.6L Inline-4), ~102 HP

A190:

M166 E19 (1.9L Inline-4), ~125 HP

A210 Evolution:

M166 E21 (2.1L Inline-4), ~140 HP

A160 Cdi:

OM668 DE17 LA (1.7L Inline-4 Turbo Diesel), ~60 HP

A170 Cdi:

OM668 DE17 LA (1.7L Inline-4 Turbo Diesel), ~75 HP

Torque Peak A160:

150 Nm @ 3000 rpm

Torque Peak A170 Cdi:

160 Nm @ 1800 rpm

Petrol:

Electronic Fuel Injection (EFI), Sequential Multipoint Fuel Injection (MPI)

Diesel:

Common Rail Direct Injection (CDI), Turbocharged and Intercooled

Standards:

Euro 3, with specific components for emissions reduction.

🔧 Transmission

Manual Gearbox:

5-speed manual transmission

Automatic Gearbox:

Autospeed 5-speed automatic transmission (optional on some models)

Drive Layout:

Front-Wheel Drive (FWD)

Automatic Transmission Fluid:

MB 236.10 or MB 236.12 (e.g., MB ATF LT 71141)

Manual Transmission Fluid:

MB 235.10 (e.g., MB Gear Oil 000 989 26 02)

📐 Dimensions

Length:

Approx. 3626 mm - 3752 mm (depending on variant)

Width:

Approx. 1719 mm

Height:

Approx. 1575 mm

Wheelbase:

Approx. 2407 mm

Curb Weight:

Approx. 1150 kg - 1350 kg (depending on engine and equipment)

Boot Capacity:

Approx. 390 liters (expandable)

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (early models); improved with later revisions, particularly regarding side impact protection (A-Class was tested multiple times).

Standard Safety:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake Assist (BAS), optional ESP (Electronic Stability Program).

Airbags:

Front airbags, optional side airbags.

Body Structure:

Unique sandwich concept construction designed for enhanced crash safety, with engine and transmission positioned beneath the passenger cabin.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player, often with options for enhanced sound systems.

Navigation:

Optional Becker Map Pilot navigation system available on some models.

Cruise Control:

Optional cruise control system available on select models.

Parking Sensors:

Optional front and rear parking sensors (Parktronic).

Interior Features:

Power windows, electric mirrors, remote central locking, climate control (manual or automatic).

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km or 1 year, whichever comes first (refer to specific model year recommendations).

Major Service Interval:

Spark plug replacement at ~60,000 km (petrol), fuel filter replacement at ~60,000 km (diesel), brake fluid change every 2 years.

Engine Oil Petrol:

MB 229.5 (e.g., 5W-40 or 0W-40, synthetic) or MB 229.1 depending on model year and engine.

Engine Oil Diesel:

MB 229.51 or MB 229.52 (low SAPS synthetic for diesel particulate filters on later models) or MB 229.3/229.31. Consult manual for exact specification based on engine and DPF presence.

Coolant:

MB 325.0 (Ethylene Glycol based coolant, blue color)

Brake Fluid:

DOT 4

Common Faults Petrol:

Ignition coil failure, MAF sensor issues, occasional electrical gremlins, wear on suspension bushings.

Common Faults Diesel:

Injector seal leaks, glow plug issues, turbocharger problems (especially if poorly maintained), potential cylinder head gasket issues on early OM668.

Body Chassis:

Corrosion can occur in wheel arches and sills, potential issues with tailgate struts and rear wiper motor.

Electrical:

Window regulator failures, instrument cluster faults, central locking issues.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury, dating back to the invention of the automobile.

W168 Introduction:

The W168 A-Class was launched in 1997 as a radical departure for Mercedes-Benz, targeting a younger demographic and the compact car segment with its innovative 'sandwich' platform.

Facelift:

A significant facelift occurred in 2001, addressing some initial criticisms regarding ride comfort, steering feel, and offering updated styling and improved safety features.

Manufacturing Locations:

Primarily manufactured at the Rastatt plant in Germany.

🏆 Awards & Recognition

Market Reception:

The A-Class was a sales success for Mercedes-Benz, particularly in Europe, establishing the brand in a new segment. However, its initial 'moose test' incident led to significant brand impact and rapid product improvements.

Safety Improvements:

Following the 1997 'moose test' incident, Mercedes-Benz swiftly implemented standard ESP and side airbags across the range, significantly enhancing its safety profile.