1997 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: 1997 Generation Generation Designation: First Generation (W168) Codes Chassis Code: W168 👋 Introduction Market Position Segment: Compact Executive...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

A-Class

Model Code:

Year:

Generation

Generation Designation:

First Generation (W168)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Executive / Premium Compact Hatchback

Unique Selling Proposition:

Innovative sandwich construction for compact exterior with spacious interior, advanced safety features, and premium Mercedes-Benz engineering.

Competitive Analysis

Key Competitors:

Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series Compact (E36/5).

Key Features

Safety Innovations:

Sandwich floor concept for enhanced crash safety and lower center of gravity, optional Electronic Stability Program (ESP).

Design Philosophy:

Maximizing interior space within compact exterior dimensions, focusing on safety and practicality.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Page Count

Page Count:

Comprehensive (Exact count not specified in product info, typically 800-1500+ pages for such manuals)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English (Assumed, standard for dealership technicians in many markets)

Format

Format:

Digital (Likely PDF, common for modern distribution)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul for all W168 engine variants (e.g., M166 petrol, OM668 diesel).

Transmission:

Service and repair procedures for manual and automatic transmissions (e.g., 5-speed manual, AUTOTRONIC continuously variable transmission).

Brakes:

Front disc, rear drum or disc (depending on model), ABS system diagnostics and repair.

Electrical System:

Comprehensive wiring diagrams, component testing, ECU diagnostics, lighting, ignition, charging systems.

Suspension:

Front McPherson strut, rear torsion beam axle. Repair, replacement of components, alignment procedures.

Steering:

Rack and pinion, power steering system diagnostics and repair.

Cooling System:

Radiator, fan, pump, thermostat, heater core, climate control system service.

Fuel System:

Fuel pump, injectors, lines, fuel tank, emissions control systems.

Body And Chassis:

Body panel repair, door mechanisms, interior trim, underbody corrosion protection.

Air Conditioning:

Refrigerant handling, component testing, leak detection, performance checks.

Safety Systems:

Airbag system (SRS) diagnostics and component replacement procedures.

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes, filter replacements, inspections.

Troubleshooting:

System-specific diagnostic flowcharts, common fault identification, step-by-step troubleshooting guides.

Repair:

Detailed step-by-step repair procedures for all major and minor components.

Overhaul:

Complete engine and transmission rebuild procedures.

Diagnostics:

On-board diagnostics (OBD-II) interpretation, sensor testing, actuator control, fault code clearing.

Calibration:

Wheel alignment specifications and procedures, basic module calibration where applicable.

Testing:

Component testing procedures using multimeter, oscilloscope, and specialized diagnostic tools.

Technical Depth

Depth:

Dealership Level / Professional Technician

Detail Level:

Includes torque specifications, tolerances, electrical resistance values, diagnostic voltage readings.

Completeness:

Vehicle-specific, not generic. Covers all factory-specified procedures.

📊 Manual Specifications

File Format

Format:

PDF (Most likely)

Searchability:

Likely includes searchable text for quick information retrieval.

Print Quality

Quality:

High-resolution diagrams and text (typical of official manuals).

Binding Type

Binding:

N/A (for digital format, but implies professional layout if printed)

Paper Type

Paper:

N/A (for digital format, but implies durable paper for physical versions)

⚙️ Engine Specifications

Primary Engine

Petrol Engines:

M166 family: 1.4L (A140), 1.6L (A160, A190), 1.9L (A190), 2.1L (A210 Evolution).

Diesel Engines:

OM668 family: 1.7L CDI (A160 CDI, A170 CDI).

Performance

Horsepower Range:

60 hp (A160 CDI) to 102 hp (A210 Evolution).

Torque Range:

95 Nm (A160 CDI) to 190 Nm (A210 Evolution).

Fuel System

Petrol Injection:

Electronic Fuel Injection (MPI/SPI variations).

Diesel Injection:

Common Rail Direct Injection (CDI) for diesel variants.

Engine Layout

Configuration:

Inline 4-cylinder, transverse mounting.

Engine Features

Timing Drive:

Chain-driven camshaft (M166), belt-driven (OM668 - though some early OM668 used chains, service manual would clarify for 1997).

🔧 Transmission

Standard

Transmission Options:

5-speed Manual Transmission.

Optional

Transmission Options:

AUTOTRONIC Continuously Variable Transmission (CVT) available on select models.

Features

Clutch Type:

Single dry plate clutch (manual).

Fluid Specifications

Manual Fluid:

Refer to manual for specific MB specification (e.g., MB 235.10 or equivalent GL-4).

Automatic Fluid:

Specific CVT fluid (e.g., MB 236.20 or equivalent, depending on exact AUTOTRONIC variant).

📐 Dimensions

Exterior

Length:

Approx. 3626 mm (standard wheelbase).

Width:

Approx. 1703 mm.

Height:

Approx. 1597 mm.

Interior

Passenger Volume:

Good for its class due to sandwich design.

Cargo

Cargo Capacity:

Flexible seating (VariO system on some models) allowing for expanded cargo space.

Weights

Curb Weight:

Approx. 1100-1250 kg depending on engine and specification.

🛡️ Safety Features

Ratings

Euro Ncap:

4 Stars (Early Euro NCAP assessment, high for its time).

Active Features

Standard Anti-lock Braking System.

Optional Electronic Stability Program (ESP).

Passive Features

Airbags:

Driver and front passenger airbags (standard), side airbags (optional).

Seatbelts:

Pre-tensioned seatbelts with belt-force limiters.

💡 Technology Features

Infotainment

Audio System:

Factory-installed radio/cassette or CD player with speaker system.

Navigation:

Not commonly available on 1997 models; later options might exist.

Driver Assistance

Cruise Control:

Optional cruise control system.

Parking Sensors:

Not available on 1997 models.

Connectivity

Phone Integration:

Not standard; aftermarket options might be present.

🔧 Maintenance

Service Intervals

Oil Change Petrol:

Typically 10,000-15,000 km or 1 year (refer to manual for specific intervals and conditions).

Oil Change Diesel:

Typically 7,500-10,000 km or 1 year for CDI (refer to manual for specific intervals and conditions).

Major Service:

Often around 40,000-60,000 km, including spark plugs, air filters, fuel filters (petrol/diesel).

Fluid Specifications

Engine Oil:

Refer to manual for MB specification (e.g., MB 229.1 or MB 229.3 for petrol, MB 229.5 or MB 228.51 for diesel) and viscosity (e.g., 10W-40, 5W-40).

Coolant:

MB specification antifreeze/coolant concentrate (e.g., G48, DB-Vollhydrauliköl-Konzentrat) mixed with distilled water.

Brake Fluid:

DOT 4 (refer to manual for specific MB specification).

Known Issues

Early Models:

Potential issues with early CDI engines (e.g., injector problems), electrical gremlins, suspension wear, AUTOTRONIC transmission behaviour.

Common Repairs:

Ignition coil packs, catalytic converters, suspension bushings, clutch wear (manual), automatic transmission servicing.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mercedes-Benz, a global leader in luxury and automotive engineering.

Model Evolution

Introduction:

Launched in 1997 as Mercedes-Benz's first foray into the compact car segment.

Design Concept:

Revolutionary 'sandwich' floor design, placing drivetrain components beneath the passenger cabin for improved safety and interior packaging.

Production

Manufacturing Locations:

Primarily Rastatt, Germany.

Production Years:

1997-2004 (W168 generation).

🏆 Awards & Recognition

Recognitions

Safety Award:

High Euro NCAP safety rating for its debut year, highlighting safety focus.