2002 Mercedes A-Class (W168) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Model Code: W168 Year: 2002 Generation Generation Code: W168 Generation Years: 1997-2004 Codes Chassis Code: W168 👋 Introduction Market Position Vehicle Segment:...

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Sku: 458965

Tags: 2002 A-Class (W168) Car Cars Mercedes Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

A-Class

Model Code:

Year:

Generation

Generation Code:

Generation Years:

1997-2004

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Subcompact/Compact Hatchback

Brand Philosophy W168:

Mercedes-Benz's entry into the premium compact car segment, focusing on safety, innovation, and practicality with its unique 'sandwich' floor concept.

Competitive Analysis

Key Competitors 2002:

Volkswagen Golf, BMW 1 Series (later generations), Audi A3, Ford Focus, Opel Astra

Key Features

Sandwich Floor Concept:

Engine and transmission mounted low and forward under the passenger compartment floor, enhancing safety in frontal impacts and creating a spacious interior.

Safety Focus:

Pioneering safety features for its class, including high crash test ratings due to the sandwich floor design.

Interior Versatility:

Highly flexible seating arrangements ('Easy-Vario-Plus' system) allowing for numerous configurations, including flat-folding rear seats and removable rear seats.

📋 Manual Details

Coverage Areas

Models Covered:

All Mercedes-Benz A-Class (W168) models for the 2002 model year

Repairs Scope:

A-Z (all repairs from minor to major)

Page Count

Estimated Page Count:

Refer to specific product listing for exact count; typically 1000+ pages for comprehensive service manuals

Manual Type

Manual Category:

Service and Repair Manual

Intended User:

Dealership Technicians, Professional Mechanics, Advanced DIY Enthusiasts

Language

Language:

English (typical for global markets; confirm with specific product listing)

Format

Format:

Likely a digital format (PDF) for easy searching and printing; physical copies also possible

File Format Details:

Searchable PDF with clickable links, high-resolution diagrams and illustrations, printable pages.

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (all variants), fuel system, cooling system, lubrication system, ignition system, exhaust system, engine control systems (ECU, sensors), powertrain control module (PCM)

Transmission:

Manual and Automatic Transmission (including Sensodrive/ASC variants), clutch, driveline components, drive shafts, differentials

Chassis:

Suspension (front and rear), steering system (power steering, steering column), brakes (hydraulic, ABS, ESP), wheels, tires

Electrical:

12V electrical system, battery, alternator, starter, lighting system (headlights, taillights, interior), wiring diagrams, fuse box locations and functions, power windows, locks, mirrors, wiper systems

Body And Interior:

Body panels, doors, hood, trunk, bumpers, interior trim, seats, airbags, HVAC system (heating, ventilation, air conditioning), SRS (Supplemental Restraint System)

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs), fault finding procedures, common problems and solutions, diagnostic tools and interfaces (OBD-II)

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement

Repair And Overhaul:

Engine repair (e.g., cylinder head, pistons, camshafts), transmission overhaul, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair

Diagnostic Procedures:

Step-by-step diagnostic flowcharts for various symptoms, sensor testing, actuator testing, ECU testing

Installation And Replacement:

Replacement of components such as alternators, starter motors, radiators, fuel pumps, sensors, interior panels, exterior trim

Technical Depth

Depth Of Coverage:

Comprehensive, covering all aspects of maintenance, diagnostics, repair, and component overhaul as performed by authorized Mercedes-Benz technicians.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Graphics Quality:

High-resolution, crisp diagrams, schematics, and photographic illustrations for clarity.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Displacement Options:

Typically 1.4L, 1.6L, 1.7L (Diesel), 1.9L, 2.1L (AMG)

Engine Types:

Inline-4 cylinder, gasoline (M166, M111 families) and diesel (OM668 family)

Performance

Typical Horsepower Range:

75 HP to 145 HP (for standard models); AMG version up to 193 HP

Typical Torque Range:

100 Nm to 205 Nm (for standard models); AMG version up to 270 Nm

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI) or common rail direct injection (CDI for diesel)

Fuel Type:

Unleaded gasoline (RON 91+); Diesel fuel

Engine Management

ECU Variants:

Various Bosch Motronic or Siemens engine control units depending on engine and transmission.

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

5-speed Automated Manual (ASC/Sensodrive)

Features

Transmission Features:

Front-wheel drive (FWD), compact transverse engine mounting.

Fluid Specs

Manual Transmission Fluid:

MB 235.10 (or equivalent API GL-4 SAE 75W-85)

Automatic Transmission Fluid:

MB 236.10 or MB 236.12 (for ASC/Sensodrive, specific ATFs apply)

📐 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)

Cargo

Cargo Volume Seats Up:

Approx. 390 liters (13.8 cu ft)

Cargo Volume Seats Down:

Approx. 1140 liters (40.3 cu ft)

Weights

Curb Weight:

Approx. 1100-1250 kg (2425-2756 lbs)

Gross Vehicle Weight:

Approx. 1650-1750 kg (3638-3858 lbs)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 stars (for early W168 models); subsequent models improved or maintained this level.

Active Features

Active Safety Systems:

ABS (Anti-lock Braking System), ESP (Electronic Stability Program), Traction Control System (ASR)

Passive Features

Passive Safety Features:

Front airbags, side airbags, seatbelt pre-tensioners, crumple zones, rigid passenger cell (due to sandwich floor concept)

💡 Technology Features

Infotainment

Audio System:

Factory fitted Mercedes-Benz radios and CD players, optional Bose sound system.

Navigation:

Optional factory navigation system (APS variants) available on some models.

Driver Assistance

Cruise Control:

Available as an option on many models.

Parking Assistance:

Rear parking sensors (optional) on some later W168 models.

Connectivity

Connectivity Features:

Basic connectivity for the era; limited Bluetooth or USB integration typically not standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, with specific intervals dependent on engine type and driving conditions (refer to manual for exact details).

Major Service Interval:

Major services usually around 30,000 km (18,600 miles) or 24 months, including checks of transmission, suspension, brakes, and other systems.

Fluid Specifications

Engine Oil Specification:

MB 229.5, MB 229.51 (synthetic oils) for gasoline engines, depending on engine variant and service interval. MB 229.51 or MB 228.51 for diesels. SAE viscosity grade typically 0W-30, 0W-40, or 5W-40.

Coolant Specification:

MB 325.0 (Ethylene Glycol based coolant, blue color)

Brake Fluid Specification:

DOT 4 (MB part number A0009890807)

Known Issues

Common Wear Items:

Front suspension components (bushings, ball joints), ignition coils, catalytic converters, clutch wear (manual), transmission control module (ASC).

Potential Electrical Issues:

Occasional issues with window regulators, central locking actuators, and certain sensor failures.

Diesel Specific Issues:

Injectors, glow plugs, and potential issues with the CDI system, especially at higher mileage or if maintenance is neglected.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Renowned for engineering excellence, safety innovation, and luxury vehicles since the late 19th century.

Model Evolution

W168 Introduction:

Introduced in 1997 as Mercedes-Benz's first foray into the compact car segment, directly challenging established European rivals.

W168 Facelift:

A significant facelift occurred in 2001, bringing updated styling, improved engines, and revised interior features, affecting the 2002 model year.

Production

Production Period:

1997-2004

Manufacturing Locations:

Primarily Rastatt, Germany; also some production in other plants depending on market needs.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Achieved high safety ratings in contemporary crash tests, particularly praised for its innovative safety design.

Ratings

Germany Car Of The Year:

The A-Class (W168) won 'Golden Steering Wheel' in Germany (1997) and was voted 'Car of the Year' in several European publications.

Certifications

Certification Standards:

Meets all relevant European automotive safety and emissions standards for its model year.