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Mercedes W168 A190 1997-2004 Service Repair Workshop Manual

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$16.99
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Chassis Code: W168 Engine Variant: A190 Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Engine Code Typical: M166.990...
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Mercedes W168 A190 1997-2004 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
A-Class
Chassis Code:
W168
Engine Variant:
A190
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Engine Code Typical:
M166.990
👋 Introduction
Market Position
Segment:
Compact hatchback
Target Audience:
Younger buyers, small families, urban commuters
Competitive Analysis
Key Rivals:
Volkswagen Golf, Ford Focus, Opel Astra, Fiat Bravo
Key Features
Design Philosophy:
Innovative Sandwich Floor Concept for enhanced safety and interior space
Unique Selling Points:
Advanced safety features for its class, compact dimensions with surprisingly spacious interior
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Workshop Manual
Language:
English
Format:
Digital (likely PDF)
Page Count Estimated:
500-1500+ pages (typical for comprehensive workshop manuals)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system
Transmission:
Manual transmission, Automatic transmission (if applicable to A190 variant), clutch system, drive shafts
Chassis:
Suspension (front and rear), steering system, braking system (ABS included)
Electrical:
Engine control unit (ECU), body control module (BCM), lighting, instrumentation, power windows, central locking, infotainment system wiring, diagnostics
Bodywork:
Body panels, doors, windows, interior trim, seats, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, spark plugs), fluid checks and top-ups, brake pad replacement, belt replacement
Diagnostics:
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), wiring diagrams for electrical systems
Repair:
Engine overhauls, transmission rebuilds, suspension component replacement, brake caliper repair, electrical component diagnosis and replacement
Adjustments:
Valve adjustments, parking brake adjustment, wheel alignment specifications
Technical Depth
Scope:
Comprehensive coverage for DIY enthusiasts and professional technicians
Detail Level:
Step-by-step instructions, torque specifications, special tool requirements, component identification
📊 Manual Specifications
File Format
Digital Type:
PDF
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality
Readability:
Designed for clear reproduction on standard printers
Binding Type
Physical Copy:
N/A (Digital Product)
Paper Type
Physical Copy:
N/A (Digital Product)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated
Displacement:
1.9 Liters (1898 cc)
Bore X Stroke:
80.0 mm x 94.0 mm (typical for M166 family)
Compression Ratio:
10.3:1 (typical)
Performance
Horsepower:
125 PS (92 kW) @ 5500 rpm
Torque:
180 Nm (133 lb-ft) @ 3600 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic or similar)
Fuel Type:
Unleaded Petrol (95 RON recommended)
Emissions
Emission Standard:
Euro 3 (depending on market and model year)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
5-speed Automatic Transmission (optional on A190)
Features
Clutch:
Hydraulically operated single dry plate clutch
Final Drive Ratio:
Typical around 3.8-4.2:1 (manual/automatic may vary)
📐 Dimensions
Exterior
Length:
3626 mm (early models), 3776 mm (facelifted models)
Width:
1719 mm
Height:
1593 mm
Wheelbase:
2373 mm
Interior
Front Headroom:
Approx. 1020 mm
Rear Legroom:
Approx. 770 mm (due to sandwich floor)
Cargo
Boot Capacity:
Approx. 390 liters (extendable to 1200 liters with rear seats folded)
Weights
Curb Weight:
Approx. 1160-1220 kg (depending on transmission and equipment)
🛡️ Safety Features
Ratings
Euro Ncap Early:
4 Stars (for pre-facelift models, with some caveats)
Euro Ncap Later:
Improved safety features and ratings post-facelift
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program (ESP) on later models
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags optional
Sandwich Floor:
Key safety feature allowing engine and transmission to slide beneath the passenger compartment in a frontal impact
Seatbelts:
Pre-tensioners and force limiters on front seatbelts
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radio/cassette or CD player, optional navigation system (APS 20, APS 30)
Speakers:
Typically 4 or 6 speaker system
Driver Assistance
Cruise Control:
Optional cruise control system
Parking Sensors:
Optional rear parking sensors (Parktronic) on later models
Connectivity
Phone Integration:
Optional hands-free telephone preparation with cradle
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15,000 km or 12 months, whichever comes first (using approved synthetic oil)
Air Filter Replacement:
Every 30,000 km or 24 months
Spark Plug Replacement:
Every 60,000 km (conventional), or 90,000 km (long-life type)
Brake Fluid Change:
Every 2 years (regardless of mileage)
Fluid Specifications
Engine Oil:
API SL/SM, ACEA A3/B4, MB-Approval 229.3 or 229.5 (e.g., Mobil 1 0W-40, Shell Helix Ultra 5W-40)
Engine Oil Capacity:
Approx. 5.0 Liters (with filter)
Coolant:
Mercedes-Benz approved G48 Antifreeze/Coolant (blue/green) or equivalent (50/50 mix with distilled water)
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-80 or 75W-90 (check specific manual for exact MB specification)
Transmission Fluid Automatic:
MB-Approval 236.10 or 236.12 (e.g., ATF 410)
Brake Fluid:
DOT 4 (MB-Approval 331.0)
Known Issues
Suspension:
Premature wear of front wishbone bushings, rear shock absorber mounts
Electrical:
Failure of the SAM (Signal Acquisition Module), faulty door lock actuators, intermittent instrument cluster issues
Engine:
Oil leaks from the oil filter housing or valve cover gasket, potential for ignition coil failure
HVAC:
Leaky heater core, non-functioning blower motor resistor
📚 Vehicle History
Brand Heritage
Manufacturer:
Mercedes-Benz AG, Germany
Model Evolution
Generation:
First generation W168
Debut Year:
1997
Facelift:
2001 (Revised styling, updated interior, improved safety features, longer wheelbase on some variants)
Production
Manufacturing Plant:
Rastatt, Germany
Production End Year:
2004 (replaced by W169 A-Class)
🏆 Awards & Recognition
Recognitions
Crash Safety Award:
Recognized for its innovative safety concept, contributing to its Euro NCAP rating
Ratings
Design Awards Consideration:
Praised for its distinctive 'mini-MPV' styling and space utilization
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