Segment:
Compact car, premium hatchback segment
Unique Selling Proposition:
Innovative 'sandwich' floor concept for enhanced safety and interior space packaging in a compact footprint
Competitors:
Volkswagen Golf, Ford Focus, Opel Astra, Renault Megane, Fiat Bravo
Design Philosophy:
Compact exterior dimensions with maximized interior space and safety, particularly crash protection via the sandwich floor.
Target Audience:
Urban dwellers, young families, individuals seeking a premium, safe, and practical compact vehicle.
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Specific Models Covered:
W168 A140
Estimated Page Count:
Over 800 pages (typical for comprehensive workshop manuals)
Type:
Workshop Repair and Service Manual
Powertrain:
Engine (M166), transmission (manual and automatic), clutch, drive shafts, differential
Chassis:
Suspension (front and rear), steering system, braking system, wheels and tires
Electrical:
Engine control unit (ECU), lighting system, instrument cluster, power windows, central locking, audio system, basic body electricals
Body:
Body structure, exterior panels, interior trim, seats, heating, ventilation, and air conditioning (HVAC)
Maintenance:
Routine inspections, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt inspection/replacement
Repair:
Engine component repair and replacement (pistons, valves, head gasket), transmission overhaul, brake caliper/rotor replacement, suspension strut replacement, steering rack repair, minor body panel repair
Diagnostics:
Troubleshooting common problems, fault code interpretation (OBD-II basics), diagnostic procedures for various systems
Troubleshooting:
Step-by-step guides for diagnosing common drivability issues, electrical faults, and mechanical failures.
Engine Overhaul:
Detailed instructions for engine disassembly, inspection, measurement, and reassembly of major components like the cylinder head, block, pistons, and crankshaft.
Electrical Schematics:
Wiring diagrams for various circuits (engine management, lighting, power accessories, etc.) are typically included, crucial for diagnosing electrical issues.
Specification Charts:
Comprehensive charts detailing all essential specifications, including torque values, clearances, fluid capacities, and wear limits.
Depth:
Comprehensive, covering routine maintenance to major component overhaul and repair. Includes detailed diagrams, torque specifications, and step-by-step instructions.
PDF Quality:
High-resolution scans, often searchable text depending on original source
Searchable:
Likely searchable if digitally created or OCR'd
Printability:
Printable from PDF viewer
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Inline-4 Cylinder, Naturally Aspirated
Engine Displacement:
1.4 Liters (1397 cc)
Valve Train:
SOHC (Single Overhead Camshaft), 8 Valves
Horsepower:
82 PS (81 bhp; 60 kW) at 5000 rpm
Torque:
130 Nm (96 lb-ft) at 3750 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (RON 95 recommended)
ECU Type:
Bosch Motronic (specific version varies by year/market)
Timing Belt Or Chain:
Timing Chain (lower maintenance)
Type:
5-speed Manual Transmission
Type:
5-speed Automatic Transmission (optional)
Manual Gear Ratios:
Detailed ratios available in manual (e.g., 1st: 3.46, 2nd: 1.95, 3rd: 1.38, 4th: 1.03, 5th: 0.86, Reverse: 3.00, Final Drive: 3.73)
Manual Transmission Fluid:
MB 235.1 / API GL-4, SAE 75W-85 or 75W-90 (check manual for exact spec)
Automatic Transmission Fluid:
MB 236.10 / ATF Dexron III (check manual for exact spec)
Length:
3626 mm (142.8 in)
Height:
1575 mm (62.0 in)
Wheelbase:
2373 mm (93.4 in)
Seating Capacity:
5 passengers
Cargo Volume:
Approx. 300 - 1050 liters (depending on rear seat configuration)
Curb Weight:
Approx. 1130 kg (2491 lbs)
Gross Vehicle Weight Rating:
Approx. 1650 kg (3638 lbs)
Towing Capacity:
Typically limited for this model, consult manual or local regulations.
Euro Ncap Rating:
4 Stars (early models, structure improved later)
ABS:
Standard (Anti-lock Braking System)
Esp:
Optional on some models (Electronic Stability Program)
Airbags:
Driver and front passenger airbags standard; side airbags optional.
Structure:
Sandwich floor structure designed to absorb and redirect impact energy, pushing engine and drivetrain under the passenger compartment in frontal crashes.
Seatbelts:
Pre-tensioners and force limiters on front seats.
Audio System:
Factory fitted radio/cassette or CD player with basic speaker system. Optional upgrades available.
Display:
Small LCD display for radio and climate control information.
Cruise Control:
Optional on some models.
Aux Input:
Rarely standard; aftermarket solutions often needed for modern device connectivity.
Climate Control:
Manual or automatic climate control systems available depending on trim level.
Power Features:
Power windows (front standard, rear optional), power mirrors standard.
Oil Change Interval:
15,000 km (9,300 miles) or 12 months, whichever comes first (for fully synthetic oil, check manual for specific oil types and intervals).
Air Filter Replacement:
Every 45,000 km (27,900 miles) or 24 months.
Cabin Filter Replacement:
Every 15,000 km (9,300 miles) or 12 months.
Spark Plug Replacement:
Every 60,000 km (37,200 miles).
Engine Oil Capacity:
Approx. 4.5 liters (4.8 US quarts) with filter change.
Engine Oil Specification:
MB 229.1 or MB 229.3 (SAE 0W-40, 5W-40, or 5W-30 depending on climate and specific oil approval, consult manual).
Coolant Specification:
MB 325.0 / MB 326.0 (Glycol-based coolant, typically blue or green, 50% mixture with distilled water).
Brake Fluid Specification:
DOT 4 (or DOT 4 Plus if specified by Mercedes-Benz).
Common Problems:
Transmission issues (especially automatic), ignition coil failure, window regulator failure, early electronic ignition module problems, corrosion on subframes, potential for oil leaks from rocker cover gasket.
Suspension Wear:
Front control arm bushings and rear axle bushings can wear over time, leading to noise and handling degradation.
Electrical Gremlins:
Intermittent issues with sensors or modules can occur, often requiring diagnostic scanning.
Brand Focus:
Mercedes-Benz is renowned for luxury, engineering quality, safety, and innovation in automotive technology.
First Generation:
The W168 marked Mercedes-Benz's entry into the compact car segment, a significant departure from their traditional larger luxury sedans and coupes. Launched in 1997.
Facelift:
A facelift occurred in 2001, introducing updated styling, improved features, and minor mechanical revisions.
Production Period:
1997-2004
Manufacturing Location:
Rastatt, Germany
Safety Awards:
While Euro NCAP gave it 4 stars, Mercedes-Benz's engineering commitment to safety was a key selling point. Later models and variations may have improved ratings.
Design Awards:
The innovative sandwich floor concept received praise for its safety benefits and packaging efficiency, though styling was sometimes polarizing.
Emissions Standards:
Complies with relevant emissions standards for its production era (e.g., Euro 3).
