🏷️ Basic Information

Make:

Mercedes-Benz

Model:

A-Class

Chassis Code:

W168

Model Year:

2004

Generation Code:

W168 (First Generation Facelift)

Manual Product Code:

Not specified in provided information

👋 Introduction

Segment:

Compact Car (C-segment)

Target Audience:

Consumers seeking premium compact transportation, often positioned as a more upscale alternative to mainstream competitors.

Key Competitors 2004:

Volkswagen Golf, Ford Focus, Vauxhall/Opel Astra, Honda Civic, Toyota Corolla

Unique Selling Points:

Sandwich floor construction (for safety and packaging), compact exterior dimensions with surprisingly spacious interior, Mercedes-Benz build quality and brand prestige.

📋 Manual Details

All Models Covered:

Yes

Repair Scope:

All Repairs A-Z

Estimated Page Count:

Variable, typically 1500-2500+ pages for comprehensive workshop manuals

Type:

Service and Repair Manual

Language:

English (Standard for dealer technicians, though originals may exist in German)

Format:

Likely digital (PDF) for ease of distribution and searchability, though historical printed versions exist

📖 Manual Coverage

Engine Management:

Engine mechanical, electronic control units (ECU), fuel injection, ignition, emissions control (OBD-II diagnostics)

Drivetrain:

Transmission (manual and automatic), clutch, differential, driveshafts, axles

Chassis:

Suspension (front and rear), steering system, wheels, tires, braking system (ABS, ESP)

Electrical System:

Wiring diagrams, battery, starter, alternator, lighting, power accessories, fuse box layouts, body control module (BCM), infotainment system wiring

Body And Interior:

Body panels, doors, windows, locks, seating, dashboard, trim components, climate control system (HVAC), SRS (airbag) system

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad inspection, belt inspections

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation, live data analysis for ECUs

Repair And Rebuild:

Engine rebuilds, transmission overhauls, brake component replacement, suspension arm replacement, electrical component repair, bodywork repair procedures

Component Replacement:

Detailed steps for replacing major and minor components across all systems

Depth:

Expert/Professional Level - Equivalent to factory workshop manual used by certified technicians

Data Specificity:

Vehicle-specific; not generic information. Includes precise torque specifications, tolerances, and diagnostic parameters.

📊 Manual Specifications

Digital Format:

PDF (most common), possibly other formats like CHM or proprietary software

Resolution:

High resolution for clear diagrams and text (if digital)

Physical Binding:

Coil-bound or perfect bound (for printed versions)

Paper Quality:

Durable, high-quality paper stock for workshop environments (for printed versions)

⚙️ Engine Specifications

Engine 1 Variant:

M166 (1.4L Inline-4)

Engine 1 Code:

A140 (e.g., M166.940)

Engine 2 Variant:

M166 (1.6L Inline-4)

Engine 2 Code:

A160 (e.g., M166.960)

Engine 3 Variant:

M166 (1.9L Inline-4)

Engine 3 Code:

A190 (e.g., M166.990)

Engine 4 Variant:

OM668 (1.7L Diesel Inline-4)

Engine 4 Code:

A170 CDI (e.g., OM668.900)

Engine 5 Variant:

OM668 (1.7L Diesel Inline-4 Turbocharged)

Engine 5 Code:

A180 CDI (e.g., OM668.900)

Horsepower Range:

60 hp (A140) to 125 hp (A190), Diesel variants 75-95 hp

Torque Range:

115 Nm (A140) to 170 Nm (A190), Diesel variants 160-180 Nm

Injection Type:

Multi-point fuel injection (MPI) for petrol, Common Rail direct injection (CDI) for diesel

Fuel Type:

Unleaded Petrol (RON 95 recommended), Diesel Fuel

Cylinder Arrangement:

Inline

Engine Placement:

Transverse Mid-engine (unique feature of W168, mounted below floor)

Drive Layout:

Front-Wheel Drive (FWD)

🔧 Transmission

Gearbox Type Petrol:

5-speed Manual

Gearbox Type Diesel:

5-speed Manual or 6-speed Manual (for some CDI models)

Automatic Gearbox:

5-speed Automatic (e.g., NAG W5A380 for petrol, optional on most models)

Transmission Fluid Type:

MB 236.10 or MB 236.12 Automatic Transmission Fluid (ATF), Manual transmission oil varies by spec (e.g., MB 235.10)

📐 Dimensions

Length:

Approx. 3626 mm (A160), 3657 mm (A190/A170 CDI)

Width:

Approx. 1719 mm

Height:

Approx. 1593 mm

Wheelbase:

Approx. 2373 mm

Boot Capacity Litres:

390 litres (seats up), 1080 litres (seats down)

Curb Weight Kg:

Approx. 1160 kg - 1280 kg depending on engine and specification

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (for the original W168 in 1999, facelifted models maintained structural integrity)

Traction Control:

ASR (Anti-Slip Regulation) - standard on most models

Stability Control:

ESP (Electronic Stability Program) - available on higher trims/optional

ABS:

Standard Anti-lock Braking System

Airbags:

Front airbags, optional side airbags, optional front and rear head airbags

Seatbelts:

Pre-tensioning front seatbelts, height-adjustable front belts

Structural Design:

Sandwich structure (underfloor engine/transmission) for enhanced occupant safety in frontal impacts.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player, optional navigation system ('APS' - Auto Pilot System).

Speaker System:

Standard 4 or 6 speaker systems, optional premium sound.

Cruise Control:

Optional cruise control (Tempomat).

Parking Assist:

Optional Parktronic parking assistance system.

Phone Integration:

Optional factory fitted hands-free telephone system with cradle.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km or 12 months, whichever comes first (service A/B schedule, varies by engine)

Major Service Intervals:

Spark plugs: ~60,000 km; Transmission fluid: ~60,000-80,000 km (depending on usage); Coolant: ~5 years or 100,000 km

Engine Oil Specification:

MB 229.5 (e.g., 0W-30, 0W-40, 5W-40, 5W-30 synthetic) - check manual for specific engine variant

Coolant Specification:

MB 325.0 / 326.0 (Ethylene Glycol based, blue/green color)

Brake Fluid Specification:

DOT 4

Common Faults Petrol:

Ignition coil failures, ABS sensor failures, MAF sensor issues, minor oil leaks from crank seals, gearbox selector cable wear.

Common Faults Diesel:

Injector seal leaks (OM668), glow plug issues, turbocharger wastegate problems, EGR valve clogging.

Common Faults General:

Corrosion on suspension components, issues with electric window regulators, aging of rubber seals and hoses, potential transmission control module (TCM) faults.

📚 Vehicle History

Manufacturer:

Mercedes-Benz, a German luxury and commercial vehicle manufacturer with a long history of automotive innovation.

W168 Introduction:

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

Facelift:

The 2004 model year represents the facelifted version of the W168 (introduced in late 2000/early 2001), featuring updated styling, engines, and features.

Production Period:

W168: 1997-2004

Manufacturing Locations:

Primarily Rastatt, Germany; also Karmann, Germany and Irwindale, USA (CKD assembly)

🏆 Awards & Recognition

Industry Accolades:

While specific awards for the 2004 facelift are less documented than the initial launch, the W168 as a model range was recognized for its innovative packaging and safety features, including the 'Safety Car of the Year' award from the German magazine Auto Motor und Sport upon its initial launch.

Owner Satisfaction:

Variable, often dependent on adherence to maintenance schedules and specific engine/transmission variants.