🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Chassis Code: W168 Variant: A160 Variant Diesel: A160 CDI Generation Generation Code: First Generation Generation Name: W168 Codes Manual Product Name: Mercedes W168 A160 A160CDI 1997-2004 Service Repair Manual Manual Product Description: Mercedes W168 A160 A160CDI 1997 1998 1999 2000 2001 2002 2003 2004 Service Repair Manual PDF 👋 Introduction Market Position Segment: Compact car, premium compact hatchback Unique Selling Proposition: Sandwich floor design for enhanced safety and interior packaging in a compact footprint. Competitive Analysis Key Competitors: Volkswagen Golf, Ford Focus, Opel Astra, BMW 1 Series (later generation), Audi A3 (later generation). Key Features Design Philosophy: Innovative 'sandwich' concept for crash safety and interior space maximization. Safety Innovation: Engine mounted parallel to the floor beneath the passenger cabin, protected by the floor structure. Powertrain Layout: Front-wheel drive (FWD) 📋 Manual Details Coverage Areas Coverage Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Covered Models: Mercedes-Benz W168 A160 (Petrol), Mercedes-Benz W168 A160 CDI (Diesel) Page Count Page Count: Detailed, estimated 1000+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, cooling system, lubrication system, fuel system (petrol and diesel), ignition system (petrol), exhaust system, emission control systems, engine electricals. Transmission: Manual transmission (5-speed), Automatic transmission (Autotronic CVT/ASC), clutch system, gearbox overhaul, differential, transmission fluid specifications and change intervals. Drivetrain: Front-wheel drive system, CV joints, driveshafts, wheel bearings, axle assembly. Suspension: Front suspension (MacPherson strut), Rear suspension (torsion beam axle), shock absorbers, springs, bushings, alignment specifications. Steering: Power steering system, steering rack, power steering pump, fluid specifications, steering column. Brakes: Front disc brakes, rear drum brakes, hydraulic system, brake fluid specifications, ABS system diagnosis and repair, brake pad and rotor replacement, parking brake. Electrical: 12V electrical system, battery, alternator, starter motor, lighting system, dashboard instruments, power windows, central locking, fuses and relays, wiring diagrams for all systems. Body And Chassis: Body shell construction, doors, hood, tailgate, bumpers, interior trim, underbody corrosion protection, chassis diagnostics. HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, blower motor, climate control diagnostics. Safety Systems: Airbag system (SRS), seatbelt pre-tensioners, ABS system. Procedures Included Maintenance: Routine maintenance tasks including oil and filter changes, air filter replacement, spark plug replacement, brake fluid flushes, coolant changes, drive belt inspection and replacement. Troubleshooting: Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting guides, error code interpretation (OBD-II where applicable). Repair: Step-by-step repair instructions for all major mechanical and electrical components, engine rebuild procedures, transmission overhauls, body panel repairs, electrical component replacement. Diagnostics: Detailed diagnostic procedures for engine management, ABS, SRS, transmission control, and other electronic systems. Includes procedures for using diagnostic tools. Specifications: Torque specifications for all fasteners, critical clearances, alignment settings, fluid capacities and types, electrical component data. Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance to complex component overhauls and system diagnostics. Detail Level: Detailed exploded diagrams, wiring schematics, diagnostic trees, and step-by-step instructions with associated specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Accessibility: Viewable on computers, tablets, and smartphones. Print Quality Printability: Printable pages for on-site reference in a workshop. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Petrol Engine Code Petrol: M166 series Displacement Petrol: 1.6 Liters (1598 cc) Configuration Petrol: Inline 4-cylinder Horsepower Petrol: 102 PS (101 hp; 75 kW) @ 5250 rpm Torque Petrol: 150 Nm (111 lb-ft) @ 4000 rpm Primary Engine Diesel Engine Code Diesel: OM668 series Displacement Diesel: 1.7 Liters (1689 cc) Configuration Diesel: Inline 4-cylinder, turbocharged Horsepower Diesel: 60 PS (59 hp; 44 kW) @ 4400 rpm (A160 CDI) Torque Diesel: 135 Nm (99 lb-ft) @ 1700 rpm (A160 CDI) Performance 0-60 Mph Petrol: Approx. 10.8 seconds 0-60 Mph Diesel: Approx. 15.2 seconds (A160 CDI) Fuel System Fuel Delivery Petrol: Electronic Fuel Injection (MPI) Fuel Type Petrol: Unleaded gasoline (RON 91+) Fuel Delivery Diesel: Common Rail Direct Injection (CDI), Turbocharged Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Type Standard: 5-speed Manual Optional Type Optional: Autotronic (ASC) Continuously Variable Transmission (CVT) Features FWD Layout: Transverse engine, front-wheel drive Clutch Type: Single dry plate clutch (Manual) 📐 Dimensions Exterior Length: Approx. 3626 mm (142.8 in) Width: Approx. 1604 mm (63.1 in) Height: Approx. 1575 mm (62.0 in) Wheelbase: Approx. 2373 mm (93.4 in) Cargo Cargo Volume: Approx. 390 liters (13.8 cu ft) (rear seats up) Weights Curb Weight Petrol: Approx. 1140 kg (2513 lb) Curb Weight Diesel: Approx. 1170 kg (2579 lb) (A160 CDI) 🛡️ Safety Features Ratings Euroncap Rating: 4 Stars (Early testing protocol, innovative for its size and era) Active Features ABS: Standard Anti-lock Braking System Esp Optional: Optional Electronic Stability Program (ESP) available...