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Mercedes W168 A-Class 1997-2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Internal Chassis Code: W168 Model Generation: First Generation Production Years Covered: 1997-2004 👋 Introduction Market Position Segment: Compact/Small Family Car Introduction Year:...
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Mercedes W168 A-Class 1997-2004 Factory Service Repair ManualMercedes W168 A-Class 1997-2004 Factory Service Repair ManualMercedes W168 A-Class 1997-2004 Factory Service Repair ManualMercedes W168 A-Class 1997-2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
A-Class
Internal Chassis Code:
W168
Model Generation:
First Generation
Production Years Covered:
1997-2004
👋 Introduction
Market Position
Segment:
Compact/Small Family Car
Introduction Year:
1997
Target Audience:
Younger buyers, urban dwellers, those seeking premium quality in a compact package.
Competitive Analysis
Key Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series (Compact), Audi A3.
Key Features
Unique Selling Points:
Sandwich floor concept for safety and interior space, advanced safety features, premium interior materials, compact dimensions with surprisingly spacious cabin.
Manual Value Proposition:
Provides DIY enthusiasts and professional mechanics with the authoritative, factory-level information needed to accurately diagnose, maintain, and repair the W168 A-Class, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Covered Model Years:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Page Count
Estimated Page Count:
Over 2000 pages (typical for factory service manuals of this scope)
Manual Type
Type:
Factory Service Repair Manual (FSM)
Language
Language:
English (as primary, often includes translations)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engine variants, including M166, M266, OM166, OM668 series; engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, starting, charging.
Transmission:
Manual and Automatic transmissions (e.g., 5-speed manual, 5-speed automatic 5G-Tronic), clutch, gearbox, torque converter, drive shafts, differentials.
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), ASR (Acceleration Slip Regulation), brake rotors, pads, calipers, lines, master cylinder, parking brake.
Suspension Steering:
Front and rear suspension systems (e.g., MacPherson struts front, independent rear suspension), shock absorbers, springs, control arms, steering rack, power steering system, steering column.
Electrical Electronics:
12V electrical system, battery, alternator, starter, fuses, relays, lighting systems (headlights, taillights, interior), wiring diagrams, ECUs (Engine Control Units), body control modules (BCM), infotainment system wiring.
Body Chassis:
Body construction, exterior panels, interior trim, doors, windows, sunroof, seats, HVAC (Heating, Ventilation, and Air Conditioning) system, body sealing, rust prevention.
Safety Restraint:
Airbag system (SRS), seat belts, pre-tensioners, accident sensor.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), fault finding procedures, symptom-based troubleshooting, wiring schematics for diagnostics.
Procedures Included
Maintenance:
Routine maintenance procedures: oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt replacement, brake fluid flush.
Repair Rebuild:
Detailed step-by-step repair and overhaul instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement.
Installation Replacement:
Guidance on the removal, installation, and replacement of all parts and assemblies, including specialized procedures for key components.
Specifications Tolerances:
Torque specifications for all fasteners, critical component clearances, alignment specifications, fluid capacities, and other vital technical data.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, crucial for electrical troubleshooting and repairs.
Technical Depth
Depth:
Complete Factory Level. Covers everything from basic maintenance and fluid changes to advanced diagnostics, component overhaul, and complete system rebuilds.
Diagnostic Capabilities:
Detailed diagnostic strategies, fault code interpretation, and step-by-step troubleshooting guides using factory diagnostic tools (e.g., STAR DIAGNOSIS).
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Typically searchable text within the PDF, allowing for quick navigation to specific topics.
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Families:
M166 (petrol), M266 (petrol - facelift), OM166 (diesel - early), OM668 (diesel - later).
Engine Examples:
A140 (1.4L), A160 (1.6L), A170 CDI (1.7L Diesel), A190 (1.9L), A200 (2.0L), A210 Evolution (2.1L).
Performance
Horsepower Range:
60 kW (82 PS) to 103 kW (140 PS) depending on engine variant.
Torque Range:
137 Nm to 220 Nm depending on engine variant.
Fuel System
Injection Type:
Multi-point fuel injection (MPI) for petrol engines, Common Rail Direct Injection (CRDI) for diesel engines.
Fuel Grade:
Unleaded gasoline (Octane 91/95/98), Diesel fuel.
🔧 Transmission
Standard
Transmission Options:
5-speed manual transmission was standard on most variants.
Optional
Transmission Options:
5-speed automatic transmission (5G-Tronic) was optional.
Features
Drive Layout:
Front-engine, Front-wheel drive (FWD).
Transmission Fluid:
Refer to manual for specific MB-approval specifications (e.g., ATF MB 236.10 for 5G-Tronic).
📐 Dimensions
Exterior
Length:
Approx. 3626-3776 mm (depending on facelift and specific model).
Width:
Approx. 1703-1716 mm.
Height:
Approx. 1575-1593 mm.
Weights
Curb Weight:
Approx. 1100-1250 kg depending on engine and equipment.
Gross Vehicle Weight:
Varies by model, typically around 1600-1750 kg.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 stars (original testing) for frontal impact, lauded for its innovative safety cell design.
Active Features
Active Safety:
Optional ESP (Electronic Stability Program), optional ASR (Acceleration Slip Regulation), ABS (Anti-lock Braking System), Brake Assist (BAS).
Passive Features
Passive Safety:
Advanced 'sandwich' floor construction for occupant protection, front airbags, side airbags, front and rear seatbelt pre-tensioners, ISOFIX child seat anchor points.
💡 Technology Features
Infotainment
Audio System:
Various Becker or Clarion radio units, optional CD changer, optional navigation system (APS).
Driver Assistance
Optional Systems:
Parktronic parking assist system (PTS).
Connectivity
Optional Features:
Optional hands-free telephone system, climate control (THERMATIC/THERMOTRONIC).
Interior Tech
Climate Control:
Manual HVAC, optional THERMATIC (automatic climate control), optional THERMOTRONIC (dual-zone automatic climate control).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km or 12 months (Flex Service System 'ASSYST'). Consult manual for exact intervals based on driving conditions.
Brake Fluid Interval:
Every 2 years (as per Mercedes-Benz standard).
Spark Plug Interval:
Refer to manual based on engine type (e.g., 60,000-100,000 km for iridium plugs).
Fluid Specifications
Engine Oil Specification:
MB 229.1, MB 229.3, MB 229.31 (e.g., 5W-40, 0W-40 synthetic).
Coolant Specification:
MB-Approval 325.0 (Antifreeze/Coolant Concentrate).
Power Steering Fluid:
MB-Approval 236.3 (or equivalent specified by Mercedes-Benz).
Known Issues
Common Wear Items:
Rear axle bushings, suspension components (control arm bushings, shock absorbers), ignition coils, catalytic converter, rust on certain body panels.
Diesel Specific Issues:
Glow plugs, injection pump issues (OM668), turbocharger problems.
Electrical Issues:
Window regulator failures, central locking issues, ABS/ESP sensor faults.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Mercedes-Benz, known for luxury, engineering excellence, and safety, entered the compact segment with the W168.
Model Evolution
Facelift:
The W168 received a significant facelift in 2001, introducing updated styling, new engine options (M266 petrol engines), and improved features.
Production
Manufacturing Location:
Primary production was at the Rastatt plant in Germany.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Praised for its innovative safety design at launch, contributing to its 4-star Euro NCAP rating.
Ratings
Design Awards:
The unique design and packaging of the W168 were generally well-received in the compact car segment.
Certifications
Manufacturing Standards:
Built to Mercedes-Benz's rigorous quality and engineering standards.
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