Segment:
Compact hatchback
Target Audience:
Value-conscious compact car buyers seeking Mercedes-Benz quality and engineering in a smaller package.
Key Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series Compact (E36/5).
Unique Selling Proposition:
Sandwich floor construction for enhanced safety and interior space utilization, compact dimensions for urban maneuverability, Mercedes-Benz brand prestige.
Innovation:
Pioneering the compact premium segment for Mercedes-Benz, focus on safety engineering.
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Engine Variants Covered:
A140 (M166.940)
Regions Of Applicability:
Global (primarily European market focus)
Estimated Page Count:
800-1200 (typical for comprehensive workshop manuals)
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Powertrain:
Engine mechanical (M166.940 1.4L), fuel system, ignition system, exhaust system, engine management (ECU) diagnostics.
Transmission:
Manual transmission (G503), automatic transmission (ASR 4-speed automatic with torque converter).
Chassis:
Front-wheel drive system, suspension (front MacPherson strut, rear semi-independent torsion beam axle), steering system (hydraulic power steering), braking system (front ventilated discs, rear drums), ABS, ESP.
Electrical Systems:
12V electrical system, battery, alternator, starter motor, lighting (headlights, taillights, interior), instruments and displays, power windows, central locking, HVAC controls, SRS airbag system.
Bodywork:
Body construction, interior trim, exterior trim, doors, hood, trunk, bumpers, glass, seals.
Maintenance:
Oil change, filter replacement, coolant service, spark plug replacement, brake fluid flush, belt inspection/replacement, air filter replacement, cabin filter replacement.
Repair Procedures:
Engine overhaul, transmission repair, suspension component replacement, brake caliper/rotor replacement, steering rack replacement, electrical component diagnosis and repair, body panel repair.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation (OBD-II), wiring diagrams, component testing procedures.
Depth Of Information:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork.
Diagnostic Capabilities:
Detailed procedures for using diagnostic tools, interpreting sensor data, and pinpointing faults.
Transmission Type:
5-speed Manual
Transmission Type:
4-speed Automatic (ASR - Automatic Shift and Select)
Automatic Transmission Modes:
Standard, Winter (Economy)
Manual Transmission Gearing:
Gear ratios specific to M166 engine and G503 gearbox
Manual Transmission Fluid:
MB 235.10 (or equivalent API GL-4, SAE 75W-80)
Automatic Transmission Fluid:
MB 236.10 (or equivalent ATF Dexron II/III)
Euro Ncap Rating:
4 Stars (for early models)
Specific Safety Features:
Sandwich construction (energy absorption zones), standard driver and front passenger airbags, optional side airbags.
Electronic Stability Program:
Optional ESP (Electronic Stability Program)
Antilock Braking System:
Standard ABS (Anti-lock Braking System)
Airbag System:
Front airbags, optional front side airbags (Thorax airbags).
Seatbelt Pretensioners:
Standard front seatbelt pre-tensioners.
Audio System:
Standard radio/cassette or CD player, optional Bose sound system on higher trims.
Display Technology:
Digital display for climate control and basic audio information.
Cruise Control:
Optional cruise control system.
Parking Assistance:
Optional parking sensors (Parktronic).
Phone Integration:
Optional Bluetooth hands-free system (later models).
Oil Change Interval:
15,000 km or 12 months, whichever comes first (flexible service system - ASSYST)
Air Filter Replacement:
Every 30,000 km or 24 months
Cabin Filter Replacement:
Every 20,000 km or 12 months
Spark Plug Replacement:
Every 60,000 km (NGK BKR5EK or equivalent)
Engine Oil Specification:
MB 229.1 (e.g., SAE 5W-40 or 10W-40)
Engine Oil Capacity Liters:
4.5 Liters (with filter change)
Coolant Specification:
MB 325.0 / 326.0 (Antifreeze/Coolant concentrate, silicate-free)
Brake Fluid Specification:
DOT 4
Common Problems:
Electronic module failures (SAM unit), premature wear of suspension components (bushings, ball joints), potential for rust in certain areas, door lock actuator issues, early models sometimes had issues with the transmission selector module.
Maintenance Recommendations:
Regular inspection of suspension components, checking for electrical system faults, ensuring proper cooling system maintenance.
Manufacturer History:
Mercedes-Benz, a historic German automotive manufacturer renowned for luxury, engineering, and safety since 1886.
W168 Introduction:
Introduced in 1997 as Mercedes-Benz's first entry into the compact car segment, aiming to attract a younger demographic and expand market reach.
Facelift:
Facelifted model introduced in 2001 with updated styling, improved features, and powertrain refinements.
Production Years:
1997-2004
Manufacturing Locations:
Mainly Rastatt, Germany, and also some production in other DaimlerChrysler facilities.
Safety Awards:
Achieved a respectable 4-star rating in Euro NCAP crash tests for its time, demonstrating Mercedes-Benz's commitment to safety even in its compact offerings.
Segment Perception:
Considered a premium compact option, offering a blend of comfort, safety, and brand prestige not typically found in its class at the time of its introduction.
