🏷️ Basic Information

Make:

Mercedes-Benz

Model:

A-Class

Chassis Code:

W168

Variant:

A160

Variant Diesel:

A160 CDI

Generation Code:

First Generation

Generation Name:

W168

Manual Product Name:

Mercedes W168 A160 A160CDI 1997-2004 Service Repair Manual

Manual Product Description:

Mercedes W168 A160 A160CDI 1997 1998 1999 2000 2001 2002 2003 2004 Service Repair Manual PDF

👋 Introduction

Segment:

Compact car, premium compact hatchback

Unique Selling Proposition:

Sandwich floor design for enhanced safety and interior packaging in a compact footprint.

Key Competitors:

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

Design Philosophy:

Innovative 'sandwich' concept for crash safety and interior space maximization.

Safety Innovation:

Engine mounted parallel to the floor beneath the passenger cabin, protected by the floor structure.

Powertrain Layout:

Front-wheel drive (FWD)

📋 Manual Details

Coverage Years:

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

Covered Models:

Mercedes-Benz W168 A160 (Petrol), Mercedes-Benz W168 A160 CDI (Diesel)

Page Count:

Detailed, estimated 1000+ pages (typical for comprehensive service manuals)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, diagnosis, cooling system, lubrication system, fuel system (petrol and diesel), ignition system (petrol), exhaust system, emission control systems, engine electricals.

Transmission:

Manual transmission (5-speed), Automatic transmission (Autotronic CVT/ASC), clutch system, gearbox overhaul, differential, transmission fluid specifications and change intervals.

Drivetrain:

Front-wheel drive system, CV joints, driveshafts, wheel bearings, axle assembly.

Suspension:

Front suspension (MacPherson strut), Rear suspension (torsion beam axle), shock absorbers, springs, bushings, alignment specifications.

Steering:

Power steering system, steering rack, power steering pump, fluid specifications, steering column.

Brakes:

Front disc brakes, rear drum brakes, hydraulic system, brake fluid specifications, ABS system diagnosis and repair, brake pad and rotor replacement, parking brake.

Electrical:

12V electrical system, battery, alternator, starter motor, lighting system, dashboard instruments, power windows, central locking, fuses and relays, wiring diagrams for all systems.

Body And Chassis:

Body shell construction, doors, hood, tailgate, bumpers, interior trim, underbody corrosion protection, chassis diagnostics.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, blower motor, climate control diagnostics.

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, ABS system.

Maintenance:

Routine maintenance tasks including oil and filter changes, air filter replacement, spark plug replacement, brake fluid flushes, coolant changes, drive belt inspection and replacement.

Troubleshooting:

Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting guides, error code interpretation (OBD-II where applicable).

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, engine rebuild procedures, transmission overhauls, body panel repairs, electrical component replacement.

Diagnostics:

Detailed diagnostic procedures for engine management, ABS, SRS, transmission control, and other electronic systems. Includes procedures for using diagnostic tools.

Specifications:

Torque specifications for all fasteners, critical clearances, alignment settings, fluid capacities and types, electrical component data.

Depth:

Comprehensive, covering everything from basic preventative maintenance to complex component overhauls and system diagnostics.

Detail Level:

Detailed exploded diagrams, wiring schematics, diagnostic trees, and step-by-step instructions with associated specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Accessibility:

Viewable on computers, tablets, and smartphones.

Printability:

Printable pages for on-site reference in a workshop.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code Petrol:

M166 series

Displacement Petrol:

1.6 Liters (1598 cc)

Configuration Petrol:

Inline 4-cylinder

Horsepower Petrol:

102 PS (101 hp; 75 kW) @ 5250 rpm

Torque Petrol:

150 Nm (111 lb-ft) @ 4000 rpm

Engine Code Diesel:

OM668 series

Displacement Diesel:

1.7 Liters (1689 cc)

Configuration Diesel:

Inline 4-cylinder, turbocharged

Horsepower Diesel:

60 PS (59 hp; 44 kW) @ 4400 rpm (A160 CDI)

Torque Diesel:

135 Nm (99 lb-ft) @ 1700 rpm (A160 CDI)

0-60 Mph Petrol:

Approx. 10.8 seconds

0-60 Mph Diesel:

Approx. 15.2 seconds (A160 CDI)

Fuel Delivery Petrol:

Electronic Fuel Injection (MPI)

Fuel Type Petrol:

Unleaded gasoline (RON 91+)

Fuel Delivery Diesel:

Common Rail Direct Injection (CDI), Turbocharged

Fuel Type Diesel:

Diesel Fuel

🔧 Transmission

Type Standard:

5-speed Manual

Type Optional:

Autotronic (ASC) Continuously Variable Transmission (CVT)

FWD Layout:

Transverse engine, front-wheel drive

Clutch Type:

Single dry plate clutch (Manual)

📐 Dimensions

Length:

Approx. 3626 mm (142.8 in)

Width:

Approx. 1604 mm (63.1 in)

Height:

Approx. 1575 mm (62.0 in)

Wheelbase:

Approx. 2373 mm (93.4 in)

Cargo Volume:

Approx. 390 liters (13.8 cu ft) (rear seats up)

Curb Weight Petrol:

Approx. 1140 kg (2513 lb)

Curb Weight Diesel:

Approx. 1170 kg (2579 lb) (A160 CDI)

🛡️ Safety Features

Euroncap Rating:

4 Stars (Early testing protocol, innovative for its size and era)

ABS:

Standard Anti-lock Braking System

Esp Optional:

Optional Electronic Stability Program (ESP) available on some models.

Airbags:

Driver and front passenger airbags, optional side airbags.

Structure:

Reinforced safety cell due to sandwich construction.

Seatbelts:

Front seatbelt pretensioners.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player, optional upgrades available.

Navigation:

Optional factory navigation system ( Becker units) on later models.

ABS Standard:

Standard Anti-lock Braking System (ABS).

Esp Availability:

Optional Electronic Stability Program (ESP) often found on higher trims or as an option.

Connectivity Features:

Limited connectivity by modern standards; features like Bluetooth would be aftermarket additions.

🔧 Maintenance

Oil Change Interval Petrol:

Every 15,000 km or 12 months, whichever comes first.

Oil Change Interval Diesel:

Every 10,000 km or 12 months, whichever comes first (CDI).

Air Filter Replacement:

Every 30,000 km or 24 months.

Fuel Filter Replacement Diesel:

Every 40,000 km or 48 months (CDI).

Spark Plug Replacement Petrol:

Every 60,000 km (Long-life spark plugs recommended).

Brake Fluid Change:

Every 2 years, regardless of mileage.

Coolant Change:

Every 5 years or 100,000 km.

Engine Oil Petrol:

API SL/SM, ACEA A3/B3, SAE 0W-40 or 5W-40 (MB-Approval 229.3 or 229.5)

Engine Oil Diesel:

API CF, ACEA B4, SAE 5W-40 (MB-Approval 229.3 or 229.5) (CDI)

Transmission Fluid Manual:

MB 235.10 (or equivalent manual transmission fluid spec)

Transmission Fluid Autotronic Cvt:

MB-Approval 236.20 (or equivalent CVT fluid)

Brake Fluid:

DOT 4 (MB-Approval 331.0)

Coolant:

Glycol-based antifreeze/coolant (MB-Approval 325.0 or 326.0)

Common Problems:

Corrosion on rear wheel arches, ignition coil failure (petrol), EGR valve issues (diesel), potential for oil leaks from engine components, HVAC blower motor resistor failure, wear on suspension bushings, premature catalytic converter failure (petrol).

📚 Vehicle History

Manufacturer:

Mercedes-Benz, known for luxury, engineering, and safety.

Introduction Year:

1997

Facelift:

Minor facelift in 2001 with updated styling and features.

Production Period:

1997 - 2004

Manufacturing Plant:

Rastatt, Germany

🏆 Awards & Recognition

Safety Award Early:

Recognized for its innovative safety features and crash performance for its class at the time of launch (Euro NCAP).

Owner Satisfaction:

Varied, often praised for comfort and build quality but faced criticism for some reliability aspects in early models. The manual addresses these common concerns.