🏷️ Basic Information

Make:

Mercedes-Benz

Model:

A-Class

Chassis Code:

W168

Model Variant:

A190

Generation:

1st Generation

Engine Code Range:

M166 (specifically M166.990)

👋 Introduction

Vehicle Class:

Compact MPV (Multi-Purpose Vehicle) / Hatchback

Segment Introduction:

The W168 A-Class represented Mercedes-Benz's first foray into the compact hatchback segment, aiming to attract a younger demographic and compete with established European rivals.

Key Competitors:

Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane, Fiat Bravo/Brava.

Unique Design:

The 'sandwich' floor design was a hallmark, allowing for a lower seating position, enhanced safety in front-end collisions (the engine and transmission could slide underneath the passenger cell), and increased interior space relative to its exterior footprint.

Safety Innovation:

Pioneered advanced safety features for its class, including standard airbags, ABS, and the optional 'Sensotronic' Brake by Wire system (later revised).

Target Audience:

DIY mechanics, independent repair shops, and Mercedes-Benz enthusiasts seeking in-depth knowledge for maintenance and repair of the W168 A190.

📋 Manual Details

Years Covered:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

Estimated Page Count:

Hundreds of pages (exact number not specified, indicating comprehensive depth)

Manual Type:

Workshop Service Repair Manual

Language:

English (assumed for typical workshop manuals of this era and origin)

Format:

Downloadable (likely PDF or similar digital format)

📖 Manual Coverage

Powertrain:

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

Transmission:

Automatic transmission (e.g., NAG 5-speed), clutch system (if applicable for manual variants, though A190 typically auto), drive shafts, differential.

Chassis And Suspension:

Front suspension (e.g., MacPherson struts, unique sandwich design), rear suspension, steering system (power steering), wheel alignment, brakes (ABS, EBD, brake system components).

Electrical And Electronics:

Wiring diagrams, battery, alternator, starter, lighting systems (headlights, taillights, interior), dashboard instruments, climate control electronics, SRS (Airbag) system, body control modules (BCM), ECU diagnostics.

Body And Interior:

Body panels, doors, windows, locks, exterior trim, interior trim, seating systems, HVAC (Heating, Ventilation, Air Conditioning) components, body repair procedures.

Maintenance:

Routine inspections, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, brake fluid flush, coolant flush, transmission fluid change, belt replacement.

Diagnostics And Troubleshooting:

Symptom-based diagnostics, fault code interpretation (OBD-II), testing procedures for electrical components, fuel system pressure testing, ignition system testing, mechanical diagnostics.

Repair And Rebuild:

Engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack replacement, electrical component repair, body panel repair, interior component repair.

Disassembly And Assembly:

Step-by-step instructions for removing and installing major components and sub-assemblies.

Depth:

Comprehensive: Covers everything from basic maintenance to complex engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format:

PDF (most likely for downloadables, ensuring broad compatibility)

Print Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding Type:

Not applicable (digital format)

Paper Type:

Not applicable (digital format)

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, naturally aspirated

Engine Code:

M166.990

Displacement:

1.9 Liters (1898 cc)

Horsepower:

125 hp (92 kW) at 5500 rpm

Torque:

180 Nm (133 lb-ft) at 4200 rpm

Compression Ratio:

10.3:1

Fuel Delivery:

Electronic Fuel Injection (Bosch Motronic)

Block Material:

Aluminum alloy

Cylinder Head Material:

Aluminum alloy

Bore X Stroke:

82.0 mm x 91.8 mm

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

🔧 Transmission

Transmission Type:

5-speed Automatic (NAG - New Automatic Gearbox)

Transmission Type:

5-speed Manual (less common for A190, but possible for some markets)

Automatic Features:

Comfort (C) and Sport (S) modes.

Automatic Transmission Fluid Type:

MB 236.10 (e.g., Shell ATF 134, Mobil ATF 134)

Automatic Transmission Fluid Capacity:

Approximately 7.0 - 8.0 liters (check manual for exact refill quantity)

📐 Dimensions

Length:

Approx. 3626 mm (142.8 in)

Width:

Approx. 1719 mm (67.7 in)

Height:

Approx. 1593 mm (62.7 in)

Wheelbase:

Approx. 2373 mm (93.4 in)

Curb Weight:

Approx. 1250 kg (2756 lbs) for automatic transmission

Gross Vehicle Weight:

Approx. 1700 kg (3748 lbs)

Cargo Volume:

Approx. 390 liters (13.8 cu ft) with rear seats up

Cargo Volume Seats Folded:

Approx. 1140 liters (40.3 cu ft) with rear seats folded

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (for earlier models, design evolved)

Anti Lock Braking System:

Standard ABS

Electronic Brakeforce Distribution:

Standard EBD

Airbags:

Driver, front passenger, side airbags (optional or standard depending on market/trim)

Seat Belts:

Pretensioners and force limiters for front seats

Crash Structure:

Reinforced passenger cell with energy-absorbing zones, 'sandwich' floor design for improved frontal crash protection.

💡 Technology Features

Radio System:

Various Mercedes-Benz Audio systems (e.g., Audio 10, Audio 30 APS) with CD/Radio functionality. Cassette decks were also common in earlier models.

Navigation:

Optional COMAND (Cockpit Management and Navigation) system available on higher trims or as an aftermarket addition.

Cruise Control:

Available as an option.

Electronic Stability Program:

Optional ESP (Electronic Stability Program) was available.

Phone Integration:

Optional integrated hands-free phone systems, often with cradle compatibility for specific Nokia models of the era.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first. (Refer to specific manual for exact intervals based on driving conditions).

Spark Plug Replacement:

Approximately every 60,000 km (37,000 miles) for standard plugs, or 100,000 km (60,000 miles) for iridium plugs (if fitted).

Brake Fluid Change:

Every 2 years, regardless of mileage.

Coolant Change:

Initial change at 15,000 km (9,300 miles) or 1 year, then every 30,000 km (18,600 miles) or 2 years thereafter.

Engine Oil Type:

MB 229.3 (e.g., SAE 0W-30, 0W-40, 5W-40, 5W-30 depending on climate and specific approval)

Engine Oil Capacity:

Approximately 4.5 liters (4.8 US quarts) with filter change.

Coolant Type:

MB-Approval 325.0 or 326.0 (Antifreeze/Coolant Concentrate, typically a silicate-free G48 formulation).

Power Steering Fluid:

MB-Approval 236.3 (e.g., Febi Bilstein 02615, Pentosin CHF 11 S).

Common Faults:

Early W168 models experienced some issues with the 'Sensotronic' brake system (leading to its discontinuation/replacement), coil packs, and some electrical gremlins. Suspension components and rust on specific areas can also be noted.

Oil Filter Example:

Mann-Filter HU 718/1 (or equivalent OEM part number).

Air Filter Example:

Mann-Filter C 20 502 (or equivalent OEM part number).

📚 Vehicle History

Manufacturer Focus:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety, historically focused on the premium sedan and coupe market.

W168 Introduction:

The W168 A-Class was introduced in 1997 as a radical departure from traditional Mercedes-Benz offerings, designed to capture a new market segment and compete with increasingly sophisticated compact cars.

Facelift:

A significant facelift occurred in 2001, introducing styling revisions, improved suspension, and updated engine options. The A190 (1.9L) was part of the pre-facelift model range.

Production Period:

1997-2004

Manufacturing Location:

Rastatt, Germany (primary manufacturing plant)

🏆 Awards & Recognition

Design Awards:

The W168 A-Class received numerous design accolades for its innovative packaging and modern styling.

Safety Perception:

Despite initial rollover controversy (addressed by Mercedes-Benz with revised suspension and ESP), the W168 was generally perceived as a safe vehicle for its class due to its design and features.