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Mercedes W168 A190 1997-2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Model Code: W168 Engine Variant: A190 Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Vehicle Platform: W168 👋...
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Mercedes W168 A190 1997-2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
A-Class
Model Code:
W168
Engine Variant:
A190
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Vehicle Platform:
W168
👋 Introduction
Market Position
Market Segment:
Compact premium hatchback segment.
Competitive Analysis
Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series Compact (E36/5).
Key Features
Design Philosophy:
Innovative sandwich floor concept ('Silver Arrow'), maximizing interior space and safety in a compact footprint.
Innovation:
Pioneering safety features and unique packaging for its time.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Page Count:
Hundreds of pages (specific count not provided, typical for factory manuals)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair procedures, component identification, torque specifications for the M166 engine family specific to the A190.
Transmission:
Service and repair of automatic and manual transmissions, including clutch operation, shift mechanisms, and hydraulic control systems.
Brakes:
Hydraulic system, ABS, ESP, brake pad replacement, rotor servicing, brake caliper overhaul, bleeding procedures.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, wheel alignment specifications.
Steering:
Power steering system, steering rack, steering column, universal joints, diagnostic procedures.
Electrical:
Complete wiring diagrams, fuse box layouts, component testing, diagnostic trouble codes (DTCs), power distribution.
HVAC:
Air conditioning system, heater core, blower motor, climate control module, refrigerant charging procedures.
Bodywork:
Body panel repair, door mechanisms, interior trim removal, glass replacement, chassis specifications.
Restraints:
Airbag system diagnostics and replacement, seatbelt mechanisms, pre-tensioner system.
Fuel System:
Fuel pump, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system.
Cooling System:
Radiator, water pump, thermostat, coolant types and capacities, cooling fan operation.
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, spark plug changes, fluid level checks.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex faults across all vehicle systems.
Repair:
Step-by-step repair instructions for component replacement, assembly, and disassembly, with detailed torque specifications.
Diagnostics:
Procedures for using diagnostic tools (e.g., STAR Diagnosis system) to read fault codes, perform actuations, and monitor live data.
Adjustments:
Calibration and adjustment procedures for various systems, including throttle body, idle control, and sensor settings.
Component Replacement:
Detailed instructions for replacing major and minor components, including engine, transmission, brakes, and electrical modules.
Wiring Diagrams:
Comprehensive and detailed wiring diagrams for all electrical systems, color-coded for clarity.
Technical Depth
Depth:
Complete factory-level technical information, suitable for professional technicians and advanced DIY enthusiasts.
Detail Level:
In-depth explanations of system operation, component function, and diagnostic logic.
Specifications:
Extensive listing of all relevant technical specifications, including torque values, clearances, fluid capacities, and electrical parameters.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick navigation to specific topics.
Print Quality
Print Quality:
High-resolution images and diagrams, suitable for printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M166.990
Engine Type:
Inline-4 Cylinder, Naturally Aspirated
Displacement:
1.9 Liters (1998 cc)
Performance
Horsepower:
125 PS (123 hp; 92 kW) at 5500 rpm
Torque:
180 Nm (133 lb-ft) at 3600 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic)
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Other
Bore X Stroke:
82.0 mm x 93.0 mm
Compression Ratio:
10.6:1
Engine Management:
ME 2.0 or ME 2.8 ECU (depending on year/market)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Getrag 285)
Optional
Type:
5-speed Automatic Transmission (Mercedes-Benz 5G-Tronic, 722.6 variant)
Features
Automatic Features:
Selectable driving programs (Economy/Sport), Tiptronic function.
Fluid Specifications
Manual Fluid:
MB 235.10 (or equivalent API GL-4) SAE 75W-85 gear oil (refer to manual for exact specification)
Automatic Fluid:
MB 236.10 or MB 236.12 ATF (Automatic Transmission Fluid) (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
3818 mm (150.3 in)
Width:
1719 mm (67.7 in)
Height:
1590 mm (62.6 in)
Wheelbase:
2513 mm (98.9 in)
Weights
Curb Weight:
Approx. 1200-1250 kg (2646-2756 lbs)
Gross Vehicle Weight:
Approx. 1600-1650 kg (3527-3638 lbs)
Cargo
Cargo Volume:
390 liters (13.8 cu ft) with rear seats up, expandable to 1140 liters (40.3 cu ft) with rear seats folded.
🛡️ Safety Features
Ratings
Euro Ncap:
4 stars (original assessment, may vary by specific testing conditions and year).
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program (Adaptive ESP in later models)
Passive Features
Airbags:
Front airbags, optional side airbags, optional window airbags.
Structure:
Sandwich floor construction designed to slide under the passenger cell in frontal impacts.
💡 Technology Features
Infotainment
Head Unit:
Various optional Mercedes-Benz audio systems (e.g., Audio 10, Audio 30) with CD or cassette players.
Navigation:
Optional Becker or Mercedes-Benz factory navigation systems.
Driver Assistance
Cruise Control:
Optional cruise control system.
Parking Assistance:
Optional rear parking sensors.
Connectivity
Telephony:
Optional hands-free telephone system with cradle.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 15,000 km or 12 months (refer to manual for specific interval based on driving conditions and oil type).
Major Service:
Scheduled around 60,000 km or 4 years, including spark plugs, transmission fluid change (automatic), coolant replacement, etc. (detailed schedule in manual).
Fluid Specifications
Engine Oil:
MB 229.3 or MB 229.5 compliant synthetic oil, viscosity SAE 0W-30 or 5W-40 (refer to manual for exact recommendation).
Coolant:
MB 325.0 (Antifreeze/Coolant concentrate) mixed with distilled water (typically 50/50 ratio).
Brake Fluid:
DOT 4 (MB 331.0 specification)
Known Issues
Common Problems:
Potential issues include gearbox synchromesh wear (manual), ABS sensor failures, front suspension bushings, starter motor issues, and electronic control module (ECU) glitches. The sandwich floor concept, while safe, could lead to water ingress into the cabin if seals fail.
Filter Part Numbers
Oil Filter:
Examples: Mann-Filter HU711/1x, Mahle OC 256 (Verify specific part number for A190).
Air Filter:
Examples: Mann-Filter C35158/1, Bosch F026400001 (Verify specific part number for A190).
📚 Vehicle History
Brand Heritage
Brand:
Mercedes-Benz: Renowned for engineering excellence, luxury, and safety since its inception.
Model Evolution
First Generation:
The W168 marked Mercedes-Benz's entry into the compact car segment, a significant departure from their traditional larger luxury vehicles.
Facelift:
A facelift occurred in 2001, introducing revised styling, updated interior features, and improved engine options.
Production
Manufacturing Location:
Rastatt, Germany.
🏆 Awards & Recognition
Recognitions
General Reputation:
While not laden with specific 'awards' in the traditional sense, the W168 was recognized for its innovative safety features and space utilization, carving out a niche in the premium compact market.
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