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Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Chassis Code: W168 Engine Variants Covered: A160, A160 CDI Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Manual...
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Distributeur:
UGS: 478170
Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
A-Class
Chassis Code:
W168
Engine Variants Covered:
A160, A160 CDI
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Manual Product Name:
Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual
👋 Introduction
Market Position
Segment:
Compact / Small Family Car
Unique Selling Proposition:
Innovative 'sandwich' floor design for enhanced safety and interior space, compact footprint with surprisingly practical interior.
Competitive Analysis
Key Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, Fiat Bravo, Renault Mégane.
Key Features
Safety Concept:
Sandwich floor principle for improved crash performance, higher seating position.
Interior Flexibility:
Moduver system (optional) allowing for easy removal and reconfiguration of rear seats.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Maintenance, Repair, Troubleshooting
Component Scope:
All mechanical and electrical systems
Page Count
Estimated Page Count:
800+
Manual Type
Type:
Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanicals (M166 series for A160 gasoline, OM668 series for A160 CDI diesel), engine management systems, fuel injection, cooling system, lubrication system, exhaust system, emissions control.
Transmission:
Manual transmission (5-speed), Automatic transmission (Autotronic continuously variable transmission - CVT), clutch system, drive shafts, differential.
Brakes:
Front disc brakes, rear drum brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake system bleeding, parking brake.
Electrical:
12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses and relays, wiring diagrams, power windows, power locks, central locking, wipers, washers, horn.
Suspension Steering:
Front McPherson strut suspension, rear torsion beam axle, power steering system (hydraulic), steering column, wheel alignment.
Body Chassis:
Body panel repair, door mechanisms, hinges, latches, interior trim, exterior trim, bumpers, chassis and frame components.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, climate control unit.
Procedures Included
Maintenance:
Routine maintenance checks, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid changes, belt inspection and replacement.
Repair:
Engine component replacement (e.g., head gasket, pistons, valves), transmission overhaul, brake caliper and rotor replacement, suspension component repair/replacement, electrical component diagnosis and repair, bodywork and cosmetic repairs.
Troubleshooting:
Diagnostic procedures for common faults, fault code interpretation (OBD-II if applicable), electrical circuit diagnosis, engine performance issues, transmission shifting problems, braking system anomalies.
Diagnostics:
Step-by-step diagnostic routines for various systems, testing procedures for sensors, actuators, and control modules.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds, electrical system diagnosis).
Detail Level:
Detailed step-by-step instructions with diagrams and illustrations.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content
Print Quality
Quality:
High resolution for clear viewing and printing of diagrams
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
A160 Gasoline Engine Code:
M166.940
A160 Gasoline Displacement:
1.6 L (1598 cc)
A160 Gasoline Configuration:
Inline-4 Cylinder
A160 Gasoline Valvetrain:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
A160 Gasoline Power Output:
102 PS (101 hp; 75 kW) at 5500 rpm
A160 Gasoline Torque:
150 Nm (111 lb-ft) at 4000 rpm
A160 Cdi Diesel Engine Code:
OM668.911
A160 Cdi Diesel Displacement:
1.7 L (1689 cc)
A160 Cdi Diesel Configuration:
Inline-4 Cylinder, turbocharged, direct injection
A160 Cdi Diesel Valvetrain:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
A160 Cdi Diesel Power Output:
75 PS (74 hp; 55 kW) at 4400 rpm
A160 Cdi Diesel Torque:
160 Nm (118 lb-ft) at 1800 rpm
Performance
A160 Gasoline 0 60Mph:
Approx. 11.0 - 12.0 seconds
A160 Cdi 0 60Mph:
Approx. 14.0 - 15.0 seconds
Fuel System
A160 Gasoline Fuel Delivery:
Multi-point Fuel Injection (MPI)
A160 Cdi Fuel Delivery:
Common Rail Direct Injection (CDI)
A160 Gasoline Recommended Fuel:
Unleaded gasoline (RON 95 recommended)
A160 Cdi Recommended Fuel:
Diesel fuel
🔧 Transmission
Standard
A160 Gasoline Standard Transmission:
5-speed Manual Transmission
A160 Cdi Standard Transmission:
5-speed Manual Transmission
Optional
A160 Gasoline Optional Transmission:
Autotronic 5-speed Automated Manual Transmission (AMT / CVT)
A160 Cdi Optional Transmission:
Autotronic 5-speed Automated Manual Transmission (AMT / CVT)
Features
Autotronic Features:
Continuously Variable Transmission (CVT) with simulated gear steps, manual shifting mode via selector lever.
Fluid Specifications
Manual Transmission Fluid:
MB Approval 235.10 (SAE 75W-85 GL-4)
Automatic Transmission Fluid:
MB Approval 236.20 (CVT Fluid)
📐 Dimensions
Exterior
Length:
approx. 3626 mm (142.8 in)
Width:
approx. 1719 mm (67.7 in)
Height:
approx. 1593 mm (62.7 in)
Wheelbase:
approx. 2373 mm (93.4 in)
Interior
Seating Capacity:
5
Cargo Volume:
Approx. 390 liters (13.8 cu ft) with rear seats up, expandable to 1216 liters (42.9 cu ft) with seats folded.
Weights
Curb Weight A160:
Approx. 1140 - 1220 kg
Curb Weight A160 Cdi:
Approx. 1200 - 1280 kg
Gross Vehicle Weight Rating:
Varies by model, typically around 1650 - 1750 kg
Towing Capacity:
Not typically specified for this model, designed primarily for passenger use.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (1999 Test) - Adult occupant protection
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program
Traction Control:
ASR (Anti-Slip Regulation) often paired with ESP
Passive Features
Airbags:
Front airbags standard. Side airbags and window airbags optional.
Seatbelts:
All seating positions equipped with three-point seatbelts. Pre-tensioners and load limiters for front seats.
Child Seat Anchors:
ISOFIX mounting points for child seats (rear seats).
💡 Technology Features
Infotainment
Head Unit:
Various factory-installed Mercedes-Benz Audio or COMAND systems depending on trim and year. May include cassette, CD player, and optional navigation.
Driver Assistance
Cruise Control:
Optional on most models.
Parking Sensors:
Rear parking sensors became more common in later models or as an option.
Connectivity
Auxiliary Input:
Rarely standard, often requires aftermarket adapter for audio devices.
Bluetooth:
Not available on original models; aftermarket solutions exist.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable, typically every 15,000 km or 1 year, indicated by 'Service A' or 'Service B' on the display (depending on driving conditions).
Air Filter Replacement:
Every 30,000 km or 2 years
Cabin Filter Replacement:
Every 30,000 km or 2 years
Fuel Filter Replacement:
Every 60,000 km (Diesel models); gasoline models typically have lifetime filters or integrated into fuel pump assembly.
Spark Plug Replacement:
Every 60,000 km (A160 gasoline)
Brake Fluid Replacement:
Every 2 years
Fluid Specifications
Engine Oil Capacity A160:
Approx. 5.0 Liters (4.2 US quarts)
Engine Oil Specification A160:
MB Approval 229.1 or 229.3 (e.g., SAE 5W-40 or 10W-40)
Engine Oil Capacity A160 Cdi:
Approx. 5.0 Liters (4.2 US quarts)
Engine Oil Specification A160 Cdi:
MB Approval 229.1 or 229.5 (e.g., SAE 5W-40 Low SAPS recommended for CDI)
Coolant Type:
MB Approved Antifreeze/Coolant, Specification 325.0 (Ethylene Glycol based, typically blue)
Power Steering Fluid:
MB Approved Hydraulic Fluid, Specification 343.0 (Green)
Known Issues
Common Faults A160 Gasoline:
Ignition coil failures, lambda sensor issues, crankshaft position sensor failures, oil leaks from valve cover gasket, premature wear of front suspension bushings.
Common Faults A160 Cdi:
Injector seal leaks, turbocharger issues (over time), glow plug failures, EGR valve clogging, wear on the Autotronic transmission clutch pack (if equipped).
General W168 Issues:
Corrosion on rear wheel arches and sills, failure of the rear door release mechanism, degradation of rubber seals and hoses.
📚 Vehicle History
Brand Heritage
Manufacturer:
DaimlerChrysler AG (Mercedes-Benz brand)
Model Evolution
Introduction Year:
1997
Facelift:
Minor facelift in 2001 with updated styling, improved interior, and revised engine options.
Generation End:
2004 (replaced by W169 A-Class)
Production
Manufacturing Plant:
Rastatt, Germany
Production Volume:
Over 1.1 million units worldwide across its lifecycle.
🏆 Awards & Recognition
Recognitions
Safety Award:
Awarded 4 stars in Euro NCAP crash tests, demonstrating good safety for its class and era.
Innovation Award:
Praised for its innovative safety concept and space efficiency upon launch.
Ratings
Reliability Perception:
Mixed. While Mercedes-Benz build quality is generally high, specific components can be prone to wear, as detailed in the manual's troubleshooting section.
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