Mercedes W168 A210 1997-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Model Code: W168 Trim Variant: A210 Evolution Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Code: W168 👋 Introduction Market Position Segment: Compact MPV / Hatchback Target Audience: Families, urban commuters seeking practicality and Mercedes-Benz quality. Competitive Analysis Key Competitors: Volkswagen Golf, Ford Focus, Opel Astra, Renault Mégane. Key Features Design Philosophy: Sandwich floor design for enhanced safety and interior space optimization. Safety Innovation: Pioneering the 'sandwich' floor concept for underfloor engine placement, increasing cabin safety. Interior Versatility: Modular seating system (optional 'Varioflex') offering high degrees of interior configurability. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Page Count: Comprehensive (Estimate: 2500+ pages) 📖 Manual Coverage Systems Covered Engine: 2.1L Inline-4 (M166.990) Engine Management: ME 3.7/2.8 (Engine Control Module - ECM diagnostics, sensors, actuators, fuel injection, ignition timing) Transmission: 5-speed Automatic (716.640 / 716.670 variants) Drivetrain: Front-Wheel Drive (FWD) Suspension: Front: MacPherson strut with lower control arms; Rear: Torsion beam axle with trailing arms Steering: Hydraulic power steering system Brakes: Front: Ventilated discs; Rear: Solid discs; ABS (Anti-lock Braking System), BAS (Brake Assist), ESP (Electronic Stability Program) Electrical System: 12V system, battery, alternator, starter, lighting, fuse box diagrams, wiring diagrams Body And Chassis: Body construction, structural components, doors, windows, bumpers, interior trim, underbody protection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant R134a, climate control units Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, evaporative emission control (EVAP) system Exhaust System: Exhaust manifold, catalytic converter, mufflers, oxygen sensors Cooling System: Radiator, coolant hoses, water pump, thermostat, expansion tank Interior Features: Seats, dashboard, door panels, airbags, seatbelts, interior lighting Exterior Features: Body panels, mirrors, door handles, sunroof (if applicable), lighting units Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, lubrication Troubleshooting: Diagnostic fault codes (DTCs), symptom-based troubleshooting guides, common issues and solutions Engine Repair: Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service Transmission Service: Transmission fluid and filter change, valve body service, torque converter replacement, transmission overhaul Brake System Service: Brake pad and rotor replacement, brake caliper service, brake fluid flush and bleed, ABS component replacement Suspension And Steering Repair: Strut replacement, control arm replacement, ball joint service, power steering pump replacement, steering rack overhaul Electrical Diagnostics: Wiring harness repair, sensor testing, actuator testing, module programming (basic) HVAC Repair: Component replacement (compressor, condenser, evaporator), refrigerant system leak testing and evacuation, climate control module diagnostics Body And Trim Repair: Panel replacement, door adjustment, window regulator repair, interior trim component installation/removal Specifications And Tolerances: Torque specifications, measurement tolerances, fluid capacities, wear limits Technical Depth Depth Level: Comprehensive (from routine maintenance to major component overhauls and diagnostics) Diagnostic Capabilities: Detailed diagnostic procedures for all major systems, including common fault codes and their likely causes. Component Overhaul: Step-by-step instructions for complete disassembly, inspection, repair, and reassembly of major components. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, essential for electrical troubleshooting. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text for quick access to information. Printability: Printable pages for on-site workshop use. Print Quality Image Resolution: High-resolution diagrams and illustrations. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: M166.990 Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 2084 cc (2.1 Liters) Bore X Stroke: 84.0 mm x 93.5 mm Compression Ratio: 10.1:1 Valve Train: SOHC (Single Overhead Camshaft), 2 valves per cylinder Performance Horsepower Ps: 140 PS @ 5500 rpm Horsepower Hp: 138 hp @ 5500 rpm Torque Nm: 205 Nm @ 3000-4300 rpm Torque Lb-Ft: 151 lb-ft @ 3000-4300 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (RON 91 / AKI 87 minimum) Fuel Tank Capacity: 54 Liters (14.3 US gallons) 🔧 Transmission Standard Transmission Type: 5-speed Automatic Transmission Code: 716.640 / 716.670 Features Transmission Control: Electronic control with adaptive shifting programs. Fluid Specifications Transmission Fluid Type: MB 236.10 (e.g., ATF 3403-M115) Fluid Capacity Transmission Fluid Capacity: Approx. 7.5 Liters (dry fill) 📐 Dimensions Exterior Length: 3776 mm (148.7 inches) Width: 1722 mm (67.8 inches) Height: 1593 mm (62.7 inches) Wheelbase: 2455 mm (96.7 inches) Front Track: 1475 mm (58.1 inches) Rear Track: 1466 mm (57.7 inches) Weights Curb Weight: Approx. 1340 kg (2954 lbs) Gross Vehicle Weight Rating: Approx. 1800 kg (3968 lbs) Cargo Luggage Capacity Min: 390 Liters (13.8 cu ft) Luggage Capacity Max: 1500 Liters (53.0 cu ft) with rear seats removed 🛡️ Safety Features Ratings Euroncap Rating: 4 Stars (Early models, tested circa 1999) Active Features ABS: Standard Anti-lock Braking System Esp: Optional Electronic Stability Program (ESP) Bas: Standard Brake Assist (BAS) Passive Features Airbags: Driver and front passenger airbags (front and side, depending...

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Type: Car

Vendor:

Sku: 500159

Collections: ALL Mercedes

Availability: In stock

Tags: 1997 1998 1999 2000 2001 2002 2003 2004 A210 Car Cars Mercedes Misc W168

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

A-Class

Model Code:

Trim Variant:

A210 Evolution

Production Years Covered:

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

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact MPV / Hatchback

Target Audience:

Families, urban commuters seeking practicality and Mercedes-Benz quality.

Competitive Analysis

Key Competitors:

Volkswagen Golf, Ford Focus, Opel Astra, Renault Mégane.

Key Features

Design Philosophy:

Sandwich floor design for enhanced safety and interior space optimization.

Safety Innovation:

Pioneering the 'sandwich' floor concept for underfloor engine placement, increasing cabin safety.

Interior Versatility:

Modular seating system (optional 'Varioflex') offering high degrees of interior configurability.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Page Count:

Comprehensive (Estimate: 2500+ pages)

📖 Manual Coverage

Systems Covered

Engine:

2.1L Inline-4 (M166.990)

Engine Management:

ME 3.7/2.8 (Engine Control Module - ECM diagnostics, sensors, actuators, fuel injection, ignition timing)

Transmission:

5-speed Automatic (716.640 / 716.670 variants)

Drivetrain:

Front-Wheel Drive (FWD)

Suspension:

Front: MacPherson strut with lower control arms; Rear: Torsion beam axle with trailing arms

Steering:

Hydraulic power steering system

Brakes:

Front: Ventilated discs; Rear: Solid discs; ABS (Anti-lock Braking System), BAS (Brake Assist), ESP (Electronic Stability Program)

Electrical System:

12V system, battery, alternator, starter, lighting, fuse box diagrams, wiring diagrams

Body And Chassis:

Body construction, structural components, doors, windows, bumpers, interior trim, underbody protection

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant R134a, climate control units

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, evaporative emission control (EVAP) system

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, oxygen sensors

Cooling System:

Radiator, coolant hoses, water pump, thermostat, expansion tank

Interior Features:

Seats, dashboard, door panels, airbags, seatbelts, interior lighting

Exterior Features:

Body panels, mirrors, door handles, sunroof (if applicable), lighting units

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, lubrication

Troubleshooting:

Diagnostic fault codes (DTCs), symptom-based troubleshooting guides, common issues and solutions

Engine Repair:

Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service

Transmission Service:

Transmission fluid and filter change, valve body service, torque converter replacement, transmission overhaul

Brake System Service:

Brake pad and rotor replacement, brake caliper service, brake fluid flush and bleed, ABS component replacement

Suspension And Steering Repair:

Strut replacement, control arm replacement, ball joint service, power steering pump replacement, steering rack overhaul

Electrical Diagnostics:

Wiring harness repair, sensor testing, actuator testing, module programming (basic)

HVAC Repair:

Component replacement (compressor, condenser, evaporator), refrigerant system leak testing and evacuation, climate control module diagnostics

Body And Trim Repair:

Panel replacement, door adjustment, window regulator repair, interior trim component installation/removal

Specifications And Tolerances:

Torque specifications, measurement tolerances, fluid capacities, wear limits

Technical Depth

Depth Level:

Comprehensive (from routine maintenance to major component overhauls and diagnostics)

Diagnostic Capabilities:

Detailed diagnostic procedures for all major systems, including common fault codes and their likely causes.

Component Overhaul:

Step-by-step instructions for complete disassembly, inspection, repair, and reassembly of major components.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems, essential for electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick access to information.

Printability:

Printable pages for on-site workshop use.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M166.990

Engine Type:

Inline 4-cylinder, naturally aspirated

Displacement:

2084 cc (2.1 Liters)

Bore X Stroke:

84.0 mm x 93.5 mm

Compression Ratio:

10.1:1

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Performance

Horsepower Ps:

140 PS @ 5500 rpm

Horsepower Hp:

138 hp @ 5500 rpm

Torque Nm:

205 Nm @ 3000-4300 rpm

Torque Lb-Ft:

151 lb-ft @ 3000-4300 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (RON 91 / AKI 87 minimum)

Fuel Tank Capacity:

54 Liters (14.3 US gallons)

🔧 Transmission

Standard

Transmission Type:

5-speed Automatic

Transmission Code:

716.640 / 716.670

Features

Transmission Control:

Electronic control with adaptive shifting programs.

Fluid Specifications

Transmission Fluid Type:

MB 236.10 (e.g., ATF 3403-M115)

Fluid Capacity

Transmission Fluid Capacity:

Approx. 7.5 Liters (dry fill)

📐 Dimensions

Exterior

Length:

3776 mm (148.7 inches)

Width:

1722 mm (67.8 inches)

Height:

1593 mm (62.7 inches)

Wheelbase:

2455 mm (96.7 inches)

Front Track:

1475 mm (58.1 inches)

Rear Track:

1466 mm (57.7 inches)

Weights

Curb Weight:

Approx. 1340 kg (2954 lbs)

Gross Vehicle Weight Rating:

Approx. 1800 kg (3968 lbs)

Cargo

Luggage Capacity Min:

390 Liters (13.8 cu ft)

Luggage Capacity Max:

1500 Liters (53.0 cu ft) with rear seats removed

🛡️ Safety Features

Ratings

Euroncap Rating:

4 Stars (Early models, tested circa 1999)

Active Features

Standard Anti-lock Braking System

Optional Electronic Stability Program (ESP)

Standard Brake Assist (BAS)

Passive Features

Airbags:

Driver and front passenger airbags (front and side, depending on trim/options). Optional rear side airbags.

Seatbelts:

Pre-tensioning front seatbelts with belt force limiters.

Crash Structure:

Advanced safety cell with energy-absorbing front and rear deformation zones, plus the patented sandwich floor for enhanced occupant protection.

💡 Technology Features

Infotainment

Audio System:

Optional Audio 10/20 CD players with radio and CD functionality. Cassette players were also common.

Navigation:

Optional Becker Traffic Pilot or similar navigation systems available on higher trims.

Driver Assistance

Cruise Control:

Optional cruise control system.

Parking Assistance:

Optional rear parking sensors (Parktronic).

Connectivity

Hands Free Calling:

Optional Mercedes-Benz hands-free communication system (Bluetooth capability may vary by model year and retrofit).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (refer to specific model year for exact intervals).

Air Filter Replacement:

Every 30,000 km (18,600 miles) or as needed based on driving conditions.

Spark Plug Replacement:

Every 60,000 km (37,200 miles) for standard plugs; longer for iridium/platinum plugs (check manual).

Brake Fluid Flush:

Every 24 months (2 years).

Transmission Fluid Service:

Every 60,000 km (37,200 miles) or as recommended by Mercedes-Benz.

Fluid Specifications

Engine Oil Specification:

MB 229.1 / 229.3 (e.g., SAE 0W-40, 5W-40, 5W-30)

Engine Oil Capacity:

Approx. 5.0 Liters (with filter change)

Coolant Type:

Mercedes-Benz Coolant Formula 325.0 / 326.0 (Antifreeze/Coolant, blue color)

Power Steering Fluid:

MB 343.0 or Pentosin CHF 11 S (Green)

Brake Fluid Type:

DOT 4

Known Issues

ABS Sensor Failure:

Premature failure of ABS wheel speed sensors can trigger ABS/ESP warning lights.

Egr Valve Clogging:

Exhaust Gas Recirculation (EGR) valve can become clogged with carbon buildup, affecting engine performance and causing rough idling.

Window Regulator Failure:

Mechanical failure of window regulators, especially in older units, leading to windows not operating.

Mass Air Flow Sensor Issues:

MAF sensor can become dirty or fail, leading to engine performance issues, check engine lights, and poor fuel economy.

Transient Shudder Automatic Transmission:

Some early models experienced torque converter shudder under light load. Software updates and fluid changes can sometimes mitigate this.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mercedes-Benz, a globally recognized luxury and automotive manufacturer known for engineering excellence and safety.

Model Evolution

First Generation:

W168, introduced in 1997. Marked Mercedes-Benz's entry into the compact car segment.

Facelift:

A minor facelift occurred in 2001, introducing updated styling, improved interior materials, and revised powertrain options.

Production

Manufacturing Location:

Rastatt, Germany

Production Period:

1997-2004

🏆 Awards & Recognition

Recognitions

Safety Recognition:

Praised for its innovative 'sandwich' floor design, which significantly improved safety in this class of vehicle.

Ratings

Crash Test Performance:

While specific awards are less common, its consistent 4-star Euro NCAP rating for its era reflected a commitment to safety.