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Mercedes W168 A210 1997-2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Model Variant: A210 Evolution Chassis Code: W168 Generation Generation: First Generation (W168) Codes Engine Codes: M166.990 (A210 Evolution) 👋 Introduction Market Position Segment: Compact Premium Hatchback Target Audience: Urban dwellers, style-conscious buyers, those seeking Mercedes-Benz quality in a smaller package. Competitive Analysis Key Competitors: BMW 3 Series Compact (E36/5), Audi A3, Volkswagen Golf GTI, Ford Focus Ghia. Key Features Design Philosophy: Sandwich concept ('sandwich floor') providing a low center of gravity and increased interior space. Distinctive 'one-box' design. Model Specific Enhancements: The A210 Evolution variant offered a more powerful engine, sportier suspension tuning, and unique styling elements compared to standard W168 models. 📋 Manual Details Coverage Areas Coverage Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Page Count Estimated Page Count: Hundreds (specific count unavailable, but typical for comprehensive factory manuals) Manual Type Manual Type: Workshop Service Repair Manual (Factory) Language Language: English (typical for North American distribution, international versions may vary) Format Format: Downloadable (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine electrical, fuel system, exhaust system, cooling system, lubrication system, ignition system, emissions control. Transmission: Automatic transmission (e.g., 5-speed Automatic Transmission, code 722.6xx series variants applicable to W168), clutch, driveline, differentials. Chassis: Front suspension, rear suspension, steering system, brake system (including ABS), wheels, tires. Electrical: Body control modules, lighting systems (headlights, taillights, interior), power windows, power seats, mirrors, wipers, horn, diagnostic connectors (OBD-II), fuses, relays, wiring diagrams. Body And Interior: Body panels, doors, hood, trunk lid, interior trim, seats, dashboard, climate control system (HVAC), safety restraint systems (airbags, seatbelts). Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, spark plug replacement, brake fluid replacement. Troubleshooting: Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues. Repair And Overhaul: Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake caliper and rotor replacement, electrical component repair and replacement. Diagnostics: Use of diagnostic scan tools, ECU testing, sensor testing, actuator testing, troubleshooting flowcharts. Specifications And Data: Torque specifications, clearances, fluid capacities, diagnostic values, wiring diagrams, component locations. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans of original factory documents, enabling clear reproduction of text, diagrams, and images. Searchable text functionality likely included. Binding Type Binding Type: N/A (Downloadable Format) Paper Type Paper Type: N/A (Downloadable Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, Naturally Aspirated Displacement: 2.1 Liters (2084 cc) Bore X Stroke: 83.0 mm x 96.0 mm (estimated, typical for M166 series) Compression Ratio: 10.0:1 (typical for this engine) Performance Horsepower: 140 hp @ 5500 rpm (approximate for A210 Evolution) Torque: 205 Nm (151 lb-ft) @ 3000-4250 rpm (approximate for A210 Evolution) Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic or similar) Fuel Type: Unleaded Petrol (Premium Unleaded Recommended) Engine Management Ignition System: Electronic Ignition (Distributorless Ignition System - DIS) Cooling System Coolant Type: Mercedes-Benz approved coolant (e.g., G48 or similar silicate-free organic acid technology - OAT coolant) Lubrication System Oil Type: SAE 0W-40 or 5W-40, API SL or higher (refer to manual for exact MB approval specifications, e.g., MB 229.3) Oil Capacity: Approx. 5.0 Liters (with filter change, refer to manual for precise capacity) 🔧 Transmission Standard Transmission Type: 5-speed Automatic Transmission (e.g., NAG1 / 722.6xx series variant) Optional Manual Transmission Option: Not typically available for the A210 Evolution model, predominantly automatic. Features Automatic Features: Electronically controlled, multiple shift programs (e.g., Comfort/Sport). Fluid Specifications Transmission Fluid Type: MB 236.10 or MB 236.12 specification Automatic Transmission Fluid (ATF) (e.g., MB 001 989 21 03 10 or equivalent) Fluid Capacities Transmission Fluid Capacity: Approx. 7.5 - 8.0 Liters (total capacity, drain and fill typically ~3.5-4.0 Liters, refer to manual for exact) 📐 Dimensions Exterior Length: Approx. 3626 mm (for early W168, later models slightly longer, refer to specific year) Width: Approx. 1719 mm Height: Approx. 1593 mm Wheelbase: Approx. 2407 mm Weights Curb Weight: Approx. 1230 - 1280 kg (depending on equipment) Gross Vehicle Weight Rating: Refer to vehicle identification plate. Towing Capacity: Typically limited for this segment, refer to manual and local regulations. Cargo Cargo Volume: Approx. 390 Liters (expandable with 'Variolock' rear seat system if equipped) 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (for W168, specific rating for A210 Evolution may vary but based on W168 platform). Active Features Braking System: Anti-lock Braking System (ABS), Electronic Stability Program (ESP) standard or optional depending on year/market. Front and rear disc brakes. Traction Control: ASR (Anti-Slip Regulation) often integrated with ESP. Passive Features Airbags: Front airbags, side airbags (optional or standard), window airbags (optional). Seatbelts: Pre-tensioners...
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Mercedes W168 A210 1997-2004 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
A-Class
Model Variant:
A210 Evolution
Chassis Code:
W168
Generation
Generation:
First Generation (W168)
Codes
Engine Codes:
M166.990 (A210 Evolution)
👋 Introduction
Market Position
Segment:
Compact Premium Hatchback
Target Audience:
Urban dwellers, style-conscious buyers, those seeking Mercedes-Benz quality in a smaller package.
Competitive Analysis
Key Competitors:
BMW 3 Series Compact (E36/5), Audi A3, Volkswagen Golf GTI, Ford Focus Ghia.
Key Features
Design Philosophy:
Sandwich concept ('sandwich floor') providing a low center of gravity and increased interior space. Distinctive 'one-box' design.
Model Specific Enhancements:
The A210 Evolution variant offered a more powerful engine, sportier suspension tuning, and unique styling elements compared to standard W168 models.
📋 Manual Details
Coverage Areas
Coverage Years:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Page Count
Estimated Page Count:
Hundreds (specific count unavailable, but typical for comprehensive factory manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual (Factory)
Language
Language:
English (typical for North American distribution, international versions may vary)
Format
Format:
Downloadable (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel system, exhaust system, cooling system, lubrication system, ignition system, emissions control.
Transmission:
Automatic transmission (e.g., 5-speed Automatic Transmission, code 722.6xx series variants applicable to W168), clutch, driveline, differentials.
Chassis:
Front suspension, rear suspension, steering system, brake system (including ABS), wheels, tires.
Electrical:
Body control modules, lighting systems (headlights, taillights, interior), power windows, power seats, mirrors, wipers, horn, diagnostic connectors (OBD-II), fuses, relays, wiring diagrams.
Body And Interior:
Body panels, doors, hood, trunk lid, interior trim, seats, dashboard, climate control system (HVAC), safety restraint systems (airbags, seatbelts).
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, spark plug replacement, brake fluid replacement.
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues.
Repair And Overhaul:
Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake caliper and rotor replacement, electrical component repair and replacement.
Diagnostics:
Use of diagnostic scan tools, ECU testing, sensor testing, actuator testing, troubleshooting flowcharts.
Specifications And Data:
Torque specifications, clearances, fluid capacities, diagnostic values, wiring diagrams, component locations.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans of original factory documents, enabling clear reproduction of text, diagrams, and images. Searchable text functionality likely included.
Binding Type
Binding Type:
N/A (Downloadable Format)
Paper Type
Paper Type:
N/A (Downloadable Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, Naturally Aspirated
Displacement:
2.1 Liters (2084 cc)
Bore X Stroke:
83.0 mm x 96.0 mm (estimated, typical for M166 series)
Compression Ratio:
10.0:1 (typical for this engine)
Performance
Horsepower:
140 hp @ 5500 rpm (approximate for A210 Evolution)
Torque:
205 Nm (151 lb-ft) @ 3000-4250 rpm (approximate for A210 Evolution)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic or similar)
Fuel Type:
Unleaded Petrol (Premium Unleaded Recommended)
Engine Management
Ignition System:
Electronic Ignition (Distributorless Ignition System - DIS)
Cooling System
Coolant Type:
Mercedes-Benz approved coolant (e.g., G48 or similar silicate-free organic acid technology - OAT coolant)
Lubrication System
Oil Type:
SAE 0W-40 or 5W-40, API SL or higher (refer to manual for exact MB approval specifications, e.g., MB 229.3)
Oil Capacity:
Approx. 5.0 Liters (with filter change, refer to manual for precise capacity)
🔧 Transmission
Standard
Transmission Type:
5-speed Automatic Transmission (e.g., NAG1 / 722.6xx series variant)
Optional
Manual Transmission Option:
Not typically available for the A210 Evolution model, predominantly automatic.
Features
Automatic Features:
Electronically controlled, multiple shift programs (e.g., Comfort/Sport).
Fluid Specifications
Transmission Fluid Type:
MB 236.10 or MB 236.12 specification Automatic Transmission Fluid (ATF) (e.g., MB 001 989 21 03 10 or equivalent)
Fluid Capacities
Transmission Fluid Capacity:
Approx. 7.5 - 8.0 Liters (total capacity, drain and fill typically ~3.5-4.0 Liters, refer to manual for exact)
📐 Dimensions
Exterior
Length:
Approx. 3626 mm (for early W168, later models slightly longer, refer to specific year)
Width:
Approx. 1719 mm
Height:
Approx. 1593 mm
Wheelbase:
Approx. 2407 mm
Weights
Curb Weight:
Approx. 1230 - 1280 kg (depending on equipment)
Gross Vehicle Weight Rating:
Refer to vehicle identification plate.
Towing Capacity:
Typically limited for this segment, refer to manual and local regulations.
Cargo
Cargo Volume:
Approx. 390 Liters (expandable with 'Variolock' rear seat system if equipped)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (for W168, specific rating for A210 Evolution may vary but based on W168 platform).
Active Features
Braking System:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP) standard or optional depending on year/market. Front and rear disc brakes.
Traction Control:
ASR (Anti-Slip Regulation) often integrated with ESP.
Passive Features
Airbags:
Front airbags, side airbags (optional or standard), window airbags (optional).
Seatbelts:
Pre-tensioners and force limiters for front seats, 3-point seatbelts for all passengers.
Body Structure:
Advanced safety cage construction, energy-absorbing crumple zones due to 'sandwich floor' design.
💡 Technology Features
Infotainment
Audio System:
Factory fitted Mercedes-Benz Audio system (e.g., Audio 10, Audio 30 series), often with CD player, cassette player, and radio. Optional CD changer.
Navigation:
Optional factory fitted navigation system (e.g., APS 30).
Driver Assistance
Stability Control:
Electronic Stability Program (ESP) and ASR (Anti-Slip Regulation) were key safety technologies for this era.
Connectivity
Phone Integration:
Optional hands-free telephony system with Bluetooth or cradle integration depending on the specific system fitted.
Climate Control
HVAC System:
Manual or automatic climate control (Thermatic/Thermotronic) with recirculation function and pollen filter.
🔧 Maintenance
Service Intervals
Oil Service:
Typically every 15,000 km or 12 months, whichever comes first. (Flexible Service System - ASSYST, refer to manual for specific vehicle configuration).
Major Service:
Refer to manual for 'Service B' or further intervals, often involving brake fluid, coolant, and cabin filter replacements.
Fluid Specifications
Brake Fluid Type:
DOT 4 (MB Spec 331.0 or equivalent, e.g., Bosch Super DOT 4)
Coolant Type:
As mentioned in engine specs: Mercedes-Benz approved coolant (e.g., G48 or similar OAT)
Power Steering Fluid:
MB Spec 236.3 (e.g., Pentosin CHF 11 S or equivalent, refer to manual for confirmation).
Known Issues
Common Problems:
Ignition coil failure, crank position sensor issues, rust on wheel arches and sills, wear on suspension bushings, ABS sensor failures, automatic transmission shift issues, potential sagging headliner.
Specific To A210 Evolution:
While generally robust, performance variants can be more susceptible to wear in drivetrain components if driven hard. Refer to manual for performance-oriented maintenance.
📚 Vehicle History
Brand Heritage
Heritage Essence:
Mercedes-Benz: Known for engineering excellence, luxury, safety, and innovation in automotive design and technology.
Model Evolution
W168 Introduction:
Launched in October 1997 as Mercedes-Benz's entry into the compact car segment, aiming to attract younger buyers and compete with established European hatchbacks.
Facelift:
Received a facelift in October 2001, with styling revisions, interior improvements, and updated engine options.
A210 Evolution Positioning:
Introduced as a sportier, more performance-oriented variant of the W168, often considered the flagship of the early A-Class line-up.
Production
Production Period:
1997-2004
Manufacturing Locations:
Rastatt, Germany; Beijing, China (for the Chinese market).
🏆 Awards & Recognition
Recognitions
Design Awards:
The W168 A-Class design was recognized for its innovative packaging and safety features, though it also faced early criticism and a recall regarding its stability in the moose test.
Ratings
Reliability Studies:
Early W168 models had some reliability concerns reported in consumer studies, but later models and specific engine/transmission combinations improved. The manual is essential for addressing specific issues.
Certifications
Safety Certifications:
Achieved good Euro NCAP safety ratings for its time, reflecting Mercedes-Benz's commitment to occupant protection.
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