2003 Mercedes A-Class (W168) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Chassis Code: W168 Model Year: 2003 Codes Internal Designation: W168 👋 Introduction Market Position Segment: Compact premium hatchback, known for its innovative...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

A-Class

Chassis Code:

Model Year:

Codes

Internal Designation:

👋 Introduction

Market Position

Segment:

Compact premium hatchback, known for its innovative sandwich floor concept and compact dimensions

Target Audience:

Urban dwellers, younger demographic, individuals seeking premium quality in a smaller package

Competitive Analysis

Competitors 2003:

Volkswagen Golf, Ford Focus, Opel Astra, BMW 1 Series (emerging)

Key Features

Innovation:

Sandwich floor design for enhanced safety and interior space optimization

Safety Focus:

High safety standards, a hallmark of Mercedes-Benz vehicles

Design:

Distinctive and modern exterior and interior styling

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Model Coverage:

All 2003 Mercedes-Benz A-Class (W168) models

Repair Scope:

A-Z comprehensive repairs

Page Count

Estimated Page Count:

Typically 800-1200+ pages (exact count not provided, but indicative of comprehensive factory-level data)

Manual Type

Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

English (standard for most official Mercedes-Benz manuals)

Format

Format:

Digital (e.g., PDF, often with searchable text and diagrams)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, engine management (ECU), emissions control

Transmission:

Manual and Automatic transmission overhaul, repair, diagnostics, clutch, driveline, CV joints

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications

Steering:

Steering rack, power steering system, steering column, wheel alignment

Brakes:

Brake system diagnostics, ABS, EBD, brake fluid specifications, caliper and rotor replacement, parking brake

Electrical:

12V electrical system, battery, alternator, starter, lighting systems, fuses, relays, wiring diagrams

Body:

Body panels, doors, hood, trunk, bumpers, seals, interior trim, glass replacement

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant, diagnostics

Safety Systems:

Airbag system diagnostics and replacement (with extreme caution and specific procedures), seatbelt mechanisms

Diagnostics:

On-Board Diagnostics (OBD-II) system, fault codes (DTCs), diagnostic tool usage

Procedures Included

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, inspections

Repair:

Component replacement, system overhauls, adjustments

Troubleshooting:

Diagnostic flowcharts, common problems and solutions, symptom-based troubleshooting

Installation:

Component installation and removal procedures

Torque Specifications:

Detailed torque values for all critical fasteners

Wiring Diagrams:

Comprehensive and detailed electrical wiring schematics for all systems

Technical Depth

Depth:

Factory-level diagnostic and repair procedures, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Tools:

Procedures for using specialized Mercedes-Benz diagnostic equipment (e.g., STAR DIAGNOSIS) may be referenced or explained conceptually

Special Tools:

Identification and usage of specific tools required for certain procedures

📊 Manual Specifications

File Format

Quality:

High-resolution digital format with clear diagrams and text

Searchability:

Likely fully searchable text for quick access to information

Print Quality

Digital Rendering:

Professionally scanned or created digital reproduction of original factory manuals

Binding Type

Physical Format If Applicable:

N/A (Digital Format)

Paper Type

Digital Format Characteristics:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Example:

M166 (e.g., 1.4L, 1.6L, 1.7L, 1.9L, 2.0L petrol variants) and OM668 (e.g., 1.7L diesel variants)

Engine Variants 2003

Petrol Options:

A 140, A 160, A 190, A 210 Evolution (details vary by market)

Diesel Options:

A 170 CDI, A 200 CDI (common rail diesel)

Performance Example A190

Displacement:

1.9 Liters (1998 cc)

Horsepower:

125 PS (92 kW) at 5600 rpm

Torque:

180 Nm (133 lb-ft) at 4300 rpm

Fuel System

Injection Type:

Multi-point Fuel Injection (MPI) for petrol, Common Rail Direct Injection (CDI) for diesel

Emission Control

Catalytic Converter:

Standard feature with OBD-II monitoring

🔧 Transmission

Standard Transmission

Type:

5-speed Manual Transmission

Optional Transmission

Type:

5-speed Automated Manual Transmission (AUTO-5 SPEED) - known as 'Softouch' or 'Sequentronic' depending on specific iteration and market

Features

Drivetrain:

Front-Wheel Drive (FWD)

Fluid Specifications

Manual Transmission Fluid:

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

Automatic Transmission Fluid:

Refer to manual for specific MB approval (e.g., MB 236.10 or similar ATF specification)

📐 Dimensions

Exterior

Length:

Approx. 3626 mm (142.8 in)

Width:

Approx. 1720 mm (67.7 in)

Height:

Approx. 1593 mm (62.7 in)

Weights

Curb Weight Example A190:

Approx. 1270 kg (2800 lbs)

Gross Vehicle Weight Rating:

Varies by model, consult manual

Cargo

Trunk Volume:

Approx. 390 liters (13.8 cu ft), expandable with folding rear seats

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4-star rating (achieved in earlier testing, reflects strong safety for its class)

Active Features

Standard Anti-lock Braking System (ABS)

Optional Electronic Stability Program (ESP)

Passive Features

Airbags:

Driver and front passenger airbags standard; optional side airbags

Crash Structure:

Reinforced passenger cell, front and rear crumple zones, innovative sandwich floor design contributing to crash protection

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM/CD radio with optional premium sound systems, steering wheel controls on some models

Navigation:

Optional factory navigation system available on higher trims

Driver Assistance

Parking Assistance:

Optional rear parking sensors (PARKTRONIC)

Connectivity

Cruise Control:

Standard or optional cruise control with speed limiter

Other Features

Rain Sensing Wipers:

Optional feature

Automatic Headlights:

Optional feature

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 1 year, whichever comes first (dependent on driving conditions and specific engine oil used; consult manual for exact intervals and service indicator reset procedure)

Major Service Interval:

Around 45,000 - 60,000 km (28,000 - 37,000 miles) or 2-3 years, including inspection of various components and fluid changes

Fluid Specifications

Engine Oil Type:

Mercedes-Benz approval 229.5 (e.g., 0W-40 or 5W-40 synthetic) for petrol engines, 229.51 or 229.52 for diesel engines (check manual for exact specifications based on engine and emissions standards)

Coolant Type:

MB-Approval 325.0 or 326.0 (Antifreeze/Coolant, typically ethylene glycol-based with silicate inhibitors, color-coded blue/green or brown depending on specific approval)

Brake Fluid Type:

DOT 4 (MB-Approval 331.0 or equivalent)

Power Steering Fluid:

Refer to manual; often MB-Approval 343.0 or similar Pentosin CHF 11 S

Known Issues

Engine Idling Issues:

Can be related to MAF sensor, spark plugs, ignition coils, or vacuum leaks

Automatic Transmission Shifting Problems:

Issues with the Softouch/Sequentronic system, control modules, or solenoids

Suspension Noise:

Worn control arm bushings, ball joints, or sway bar links

Electrical Gremlins:

While generally reliable, age-related issues with sensors, wiring harnesses, or the CAN bus system can occur

Diesel Glow Plugs:

Glow plug failure can impact cold starts on CDI models

📚 Vehicle History

Brand Heritage

Manufacturer:

Mercedes-Benz, renowned for engineering excellence, safety, and luxury

Model Evolution

Introduction Year:

1997 (first generation W168)

Facelift:

Facelifted model introduced in 2001, with styling and equipment updates

Production

Manufacturing Location:

Rastatt, Germany (primary facility), and potentially other contract manufacturing sites

Production Years

Generation 1 W168:

1997-2004

🏆 Awards & Recognition

Recognitions

Safety Awards:

The W168 A-Class was recognized for its innovative safety features and strong crash test performance for its era

Ratings

Consumer Reports Historical:

Specific ratings vary by year and market, but often praised for build quality and safety, with some attention to minor issues like sensors or electronics

Certifications

Manufacturing Standards:

Produced under stringent Mercedes-Benz quality control and manufacturing standards