🏷️ Basic Information

Make:

Mercedes-Benz

Model:

A-Class

Model Code:

W168

Variant:

A190

Model Years Covered:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

Engine Code Primary:

M166.990

Chassis Code:

W168

👋 Introduction

Segment:

Compact Executive Hatchback

Positioning:

The W168 A-Class represented Mercedes-Benz's entry into the premium compact segment, designed to offer Mercedes-Benz quality, safety, and innovation in a smaller, more accessible package. It was known for its innovative 'sandwich' floor concept for enhanced safety and interior space utilization.

Key Competitors:

BMW 3 Series Compact (E36/5), Audi A3 (8L), Volkswagen Golf (Mk4), Ford Focus.

Unique Selling Points:

Sandwich floor design for safety and packaging, innovative compact powertrain, Mercedes-Benz build quality and brand prestige, advanced safety features for its class.

📋 Manual Details

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

Page Count Estimate:

Approximately 2000+ pages (typical for comprehensive Mercedes workshop manuals)

Digital Searchability:

Yes, text-searchable PDF

📖 Manual Coverage

Engine:

Complete overhaul, tuning, diagnosis, cooling system, lubrication system, fuel system (injection, pump, filters), emission control systems (catalytic converter, O2 sensors), ignition system (coils, plugs, sensors), engine management (ECU).

Transmission:

Automatic transmission (type 722.6 '5G-Tronic' likely for A190), clutch, torque converter, gear shift mechanism, transmission control module, fluid and filter replacement, rebuilding procedures.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake lines, master cylinder, brake booster, parking brake, hydraulic system.

Suspension Steering:

Front and rear suspension components (struts, springs, control arms, bushings), power steering system, steering rack, steering column, wheel alignment specifications.

Electrical Electronics:

Complete wiring diagrams, lighting systems, starting and charging systems (alternator, starter), battery, instrument cluster, interior and exterior lighting, body control modules, fuse box layouts, diagnostic connector (OBD-II).

Bodywork Chassis:

Body panel removal and installation, door mechanisms, hood, trunk, bumpers, glass replacement, interior trim, chassis structural components, rust prevention and repair.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant system service, blower motor, climate control unit, cabin air filter.

Infotainment Comfort:

Radio, navigation system, speaker installation, climate controls, power windows, central locking, seat adjustments.

Maintenance:

Scheduled maintenance intervals, oil change procedures and fluid specifications, filter replacements (oil, air, fuel, cabin), spark plug replacement, brake fluid flush, coolant change.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation, diagnostic tool usage (e.g., STAR diagnostic system principles).

Repair Rebuild:

Step-by-step instructions for component removal, installation, and rebuilding of major mechanical and electrical systems.

Technical Specifications:

Torque values for all fasteners, clearances, tolerances, wiring diagrams, vacuum routing, component identification.

Safety Systems:

Airbag system service precautions, SRS (Supplemental Restraint System) component replacement, seatbelt inspection.

Emissions Control Service:

Detailed procedures for diagnosis and repair of emission control components, including exhaust gas recirculation (EGR) if applicable, catalytic converter checks, and evaporative emission control (EVAP) systems.

Depth:

Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed diagrams, exploded views, and precise specifications for repair and overhaul.

Target Audience:

Professional Mercedes-Benz technicians, independent repair shops, and knowledgeable DIY enthusiasts seeking in-depth repair information.

Diagnostic Tools Mention:

Likely references or assumes knowledge of diagnostic tools like the Mercedes-Benz 'STAR' diagnostic system or equivalent OBD-II scanners for electronic troubleshooting.

📊 Manual Specifications

File Type:

PDF

Print Quality:

High-resolution, suitable for printing individual sections or the entire manual.

Searchability:

Text-searchable, allowing for quick retrieval of information using keywords.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness:

Comprehensive workshop manual covering all aspects of maintenance, repair, troubleshooting, and diagnostics for the specified W168 A190 models.

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, naturally aspirated

Displacement:

1.9 Liters (1898 cc)

Bore X Stroke:

82.0 mm x 93.7 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Horsepower:

125 hp (92 kW) @ 5500 rpm

Torque:

180 Nm (133 lb-ft) @ 3600 rpm

Fuel Delivery:

Electronic Fuel Injection (Bosch Motronic M5.9 or similar)

Fuel Type:

Unleaded Gasoline (RON 95 recommended)

Engine Oil Type:

API SL or ACEA A3/B3, SAE 0W-30 or 0W-40 (or as specified by Mercedes-Benz)

Engine Oil Capacity:

Approx. 5.0 Liters (with filter)

Coolant Type:

Mercedes-Benz approved Antifreeze/Coolant (Glysantin G48 or equivalent), 50/50 mix

🔧 Transmission

Transmission Type:

5-speed Automatic (likely 722.6 5G-Tronic)

Manual Transmission Option:

Not typically available for A190; primarily automatic.

Transmission Control:

Electronic control with multiple modes (e.g., Comfort, Sport - depending on ECU).

Transmission Fluid Type:

MB 236.10 (e.g., ATF Dexron III or equivalent, check specific model VIN for exact spec)

Transmission Fluid Capacity:

Approx. 7.0 - 8.0 Liters (for total fill, including torque converter)

📐 Dimensions

Length:

Approx. 3626 mm (early models) to 3776 mm (later facelift)

Width:

Approx. 1719 mm

Height:

Approx. 1593 mm

Wheelbase:

Approx. 2373 mm

Luggage Capacity:

Approx. 390 Liters (expandable with sliding rear seat)

Curb Weight:

Approx. 1265 kg

Gross Vehicle Weight:

Approx. 1765 kg

Towing Capacity:

Typically not recommended or limited for this model.

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (1999), with advanced 'sandwich' floor safety concept contributing to occupant protection.

Active Safety:

ABS (Anti-lock Braking System), BAS (Brake Assist System), optional ESP (Electronic Stability Program), Traction Control.

Passive Safety:

Front airbags, side airbags (optional), pre-tensioning seatbelts, crumple zones, reinforced 'sandwich' floor structure, advanced headlamp leveling.

💡 Technology Features

Infotainment System:

Audio 10 or Audio 30 (optional Becker units), CD player, radio, possibly cassette player. Higher trims might have optional navigation. Speaker configurations vary.

Driver Assistance Features:

ABS, Brake Assist (BAS), optional ESP. Cruise control available on some models.

Connectivity Options:

Limited by era. Optional CD changer integration. No standard Bluetooth or USB connectivity.

Climate Control System:

Manual climate control or optional automatic climate control (THERMATIC).

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km or 1 year, whichever comes first (check owner's manual for specific recommendations).

Air Filter Replacement:

Every 30,000 km or 2 years.

Spark Plug Replacement:

Every 60,000 km (check type: copper, platinum, or iridium).

Brake Fluid Flush:

Every 2 years.

Coolant Change:

Every 5 years or 100,000 km.

Brake Fluid Type:

DOT 4

Power Steering Fluid:

Mercedes-Benz specification hydraulic fluid or Pentosin CHF 11S (verify with VIN)

Common Problems:

Front suspension wear (bushings, ball joints), ignition coil failures, window regulator issues, ABS/ESP sensor faults, corrosion on specific body panels (wheel arches, sills), transmission selector module issues, MAF sensor problems.

📚 Vehicle History

Brand History:

Mercedes-Benz, founded in 1926, is renowned for luxury, engineering excellence, and pioneering automotive safety features. The W168 was a significant departure, aiming to expand the brand's appeal.

Generation Launch:

First generation W168 launched in 1997.

Facelift:

Facelifted model introduced in 2001, featuring revised styling, updated engines, and improved interior features.

Production Period:

1997 - 2004

Manufacturing Locations:

Rastatt, Germany; Sindelfingen, Germany; and also assembled in China for the Chinese market.

🏆 Awards & Recognition

Design Awards:

While specific design awards are not widely publicized, the W168's innovative packaging and safety features were acknowledged within the automotive industry.

Safety Ratings Summary:

Positive safety ratings for its time, particularly due to the sandwich floor concept and standard safety equipment, contributing to its 4-star Euro NCAP rating.