Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Chassis Code: W168 Engine Variants Covered: A160, A160 CDI Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Manual Product Name: Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual 👋 Introduction Market Position Segment: Compact / Small Family Car Unique Selling Proposition: Innovative 'sandwich' floor design for enhanced safety and interior space, compact footprint with surprisingly practical interior. Competitive Analysis Key Competitors: Volkswagen Golf, Ford Focus, Opel Astra, Fiat Bravo, Renault Mégane. Key Features Safety Concept: Sandwich floor principle for improved crash performance, higher seating position. Interior Flexibility: Moduver system (optional) allowing for easy removal and reconfiguration of rear seats. 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Repair, Troubleshooting Component Scope: All mechanical and electrical systems Page Count Estimated Page Count: 800+ Manual Type Type: Workshop Repair Manual / Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine mechanicals (M166 series for A160 gasoline, OM668 series for A160 CDI diesel), engine management systems, fuel injection, cooling system, lubrication system, exhaust system, emissions control. Transmission: Manual transmission (5-speed), Automatic transmission (Autotronic continuously variable transmission - CVT), clutch system, drive shafts, differential. Brakes: Front disc brakes, rear drum brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake system bleeding, parking brake. Electrical: 12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses and relays, wiring diagrams, power windows, power locks, central locking, wipers, washers, horn. Suspension Steering: Front McPherson strut suspension, rear torsion beam axle, power steering system (hydraulic), steering column, wheel alignment. Body Chassis: Body panel repair, door mechanisms, hinges, latches, interior trim, exterior trim, bumpers, chassis and frame components. HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, climate control unit. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid changes, belt inspection and replacement. Repair: Engine component replacement (e.g., head gasket, pistons, valves), transmission overhaul, brake caliper and rotor replacement, suspension component repair/replacement, electrical component diagnosis and repair, bodywork and cosmetic repairs. Troubleshooting: Diagnostic procedures for common faults, fault code interpretation (OBD-II if applicable), electrical circuit diagnosis, engine performance issues, transmission shifting problems, braking system anomalies. Diagnostics: Step-by-step diagnostic routines for various systems, testing procedures for sensors, actuators, and control modules. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds, electrical system diagnosis). Detail Level: Detailed step-by-step instructions with diagrams and illustrations. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content Print Quality Quality: High resolution for clear viewing and printing of diagrams Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine A160 Gasoline Engine Code: M166.940 A160 Gasoline Displacement: 1.6 L (1598 cc) A160 Gasoline Configuration: Inline-4 Cylinder A160 Gasoline Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder A160 Gasoline Power Output: 102 PS (101 hp; 75 kW) at 5500 rpm A160 Gasoline Torque: 150 Nm (111 lb-ft) at 4000 rpm A160 Cdi Diesel Engine Code: OM668.911 A160 Cdi Diesel Displacement: 1.7 L (1689 cc) A160 Cdi Diesel Configuration: Inline-4 Cylinder, turbocharged, direct injection A160 Cdi Diesel Valvetrain: DOHC (Double Overhead Camshaft), 4 valves per cylinder A160 Cdi Diesel Power Output: 75 PS (74 hp; 55 kW) at 4400 rpm A160 Cdi Diesel Torque: 160 Nm (118 lb-ft) at 1800 rpm Performance A160 Gasoline 0 60Mph: Approx. 11.0 - 12.0 seconds A160 Cdi 0 60Mph: Approx. 14.0 - 15.0 seconds Fuel System A160 Gasoline Fuel Delivery: Multi-point Fuel Injection (MPI) A160 Cdi Fuel Delivery: Common Rail Direct Injection (CDI) A160 Gasoline Recommended Fuel: Unleaded gasoline (RON 95 recommended) A160 Cdi Recommended Fuel: Diesel fuel 🔧 Transmission Standard A160 Gasoline Standard Transmission: 5-speed Manual Transmission A160 Cdi Standard Transmission: 5-speed Manual Transmission Optional A160 Gasoline Optional Transmission: Autotronic 5-speed Automated Manual Transmission (AMT / CVT) A160 Cdi Optional Transmission: Autotronic 5-speed Automated Manual Transmission (AMT / CVT) Features Autotronic Features: Continuously Variable Transmission (CVT) with simulated gear steps, manual shifting mode via selector lever. Fluid Specifications Manual Transmission Fluid: MB Approval 235.10 (SAE 75W-85 GL-4) Automatic Transmission Fluid: MB Approval 236.20 (CVT Fluid) 📐 Dimensions Exterior 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) Interior Seating Capacity: 5 Cargo Volume: Approx. 390 liters (13.8 cu ft) with rear seats up, expandable to 1216 liters (42.9 cu ft) with seats folded. Weights Curb Weight A160: Approx. 1140 - 1220 kg Curb Weight A160 Cdi: Approx. 1200 - 1280 kg Gross Vehicle Weight Rating: Varies by model, typically around 1650 - 1750 kg Towing Capacity: Not typically specified for this model, designed primarily...

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Sku: 478170

Collections: ALL Mercedes

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Tags: 1997 1998 1999 2000 2001 2002 2003 2004 A160 A160CDI Car Cars Mercedes Misc W168

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

A-Class

Chassis Code:

Engine Variants Covered:

A160, A160 CDI

Production Years Covered:

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

Codes

Manual Product Name:

Mercedes W168 A160 A160CDI 1997-2004 Workshop Repair Manual

👋 Introduction

Market Position

Segment:

Compact / Small Family Car

Unique Selling Proposition:

Innovative 'sandwich' floor design for enhanced safety and interior space, compact footprint with surprisingly practical interior.

Competitive Analysis

Key Competitors:

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

Key Features

Safety Concept:

Sandwich floor principle for improved crash performance, higher seating position.

Interior Flexibility:

Moduver system (optional) allowing for easy removal and reconfiguration of rear seats.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Maintenance, Repair, Troubleshooting

Component Scope:

All mechanical and electrical systems

Page Count

Estimated Page Count:

Manual Type

Type:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanicals (M166 series for A160 gasoline, OM668 series for A160 CDI diesel), engine management systems, fuel injection, cooling system, lubrication system, exhaust system, emissions control.

Transmission:

Manual transmission (5-speed), Automatic transmission (Autotronic continuously variable transmission - CVT), clutch system, drive shafts, differential.

Brakes:

Front disc brakes, rear drum brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake system bleeding, parking brake.

Electrical:

12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses and relays, wiring diagrams, power windows, power locks, central locking, wipers, washers, horn.

Suspension Steering:

Front McPherson strut suspension, rear torsion beam axle, power steering system (hydraulic), steering column, wheel alignment.

Body Chassis:

Body panel repair, door mechanisms, hinges, latches, interior trim, exterior trim, bumpers, chassis and frame components.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, climate control unit.

Procedures Included

Maintenance:

Routine maintenance checks, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid changes, belt inspection and replacement.

Repair:

Engine component replacement (e.g., head gasket, pistons, valves), transmission overhaul, brake caliper and rotor replacement, suspension component repair/replacement, electrical component diagnosis and repair, bodywork and cosmetic repairs.

Troubleshooting:

Diagnostic procedures for common faults, fault code interpretation (OBD-II if applicable), electrical circuit diagnosis, engine performance issues, transmission shifting problems, braking system anomalies.

Diagnostics:

Step-by-step diagnostic routines for various systems, testing procedures for sensors, actuators, and control modules.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds, electrical system diagnosis).

Detail Level:

Detailed step-by-step instructions with diagrams and illustrations.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content

Print Quality

Quality:

High resolution for clear viewing and printing of diagrams

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

A160 Gasoline Engine Code:

M166.940

A160 Gasoline Displacement:

1.6 L (1598 cc)

A160 Gasoline Configuration:

Inline-4 Cylinder

A160 Gasoline Valvetrain:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

A160 Gasoline Power Output:

102 PS (101 hp; 75 kW) at 5500 rpm

A160 Gasoline Torque:

150 Nm (111 lb-ft) at 4000 rpm

A160 Cdi Diesel Engine Code:

OM668.911

A160 Cdi Diesel Displacement:

1.7 L (1689 cc)

A160 Cdi Diesel Configuration:

Inline-4 Cylinder, turbocharged, direct injection

A160 Cdi Diesel Valvetrain:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

A160 Cdi Diesel Power Output:

75 PS (74 hp; 55 kW) at 4400 rpm

A160 Cdi Diesel Torque:

160 Nm (118 lb-ft) at 1800 rpm

Performance

A160 Gasoline 0 60Mph:

Approx. 11.0 - 12.0 seconds

A160 Cdi 0 60Mph:

Approx. 14.0 - 15.0 seconds

Fuel System

A160 Gasoline Fuel Delivery:

Multi-point Fuel Injection (MPI)

A160 Cdi Fuel Delivery:

Common Rail Direct Injection (CDI)

A160 Gasoline Recommended Fuel:

Unleaded gasoline (RON 95 recommended)

A160 Cdi Recommended Fuel:

Diesel fuel

🔧 Transmission

Standard

A160 Gasoline Standard Transmission:

5-speed Manual Transmission

A160 Cdi Standard Transmission:

5-speed Manual Transmission

Optional

A160 Gasoline Optional Transmission:

Autotronic 5-speed Automated Manual Transmission (AMT / CVT)

A160 Cdi Optional Transmission:

Autotronic 5-speed Automated Manual Transmission (AMT / CVT)

Features

Autotronic Features:

Continuously Variable Transmission (CVT) with simulated gear steps, manual shifting mode via selector lever.

Fluid Specifications

Manual Transmission Fluid:

MB Approval 235.10 (SAE 75W-85 GL-4)

Automatic Transmission Fluid:

MB Approval 236.20 (CVT Fluid)

📐 Dimensions

Exterior

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)

Interior

Seating Capacity:

Cargo Volume:

Approx. 390 liters (13.8 cu ft) with rear seats up, expandable to 1216 liters (42.9 cu ft) with seats folded.

Weights

Curb Weight A160:

Approx. 1140 - 1220 kg

Curb Weight A160 Cdi:

Approx. 1200 - 1280 kg

Gross Vehicle Weight Rating:

Varies by model, typically around 1650 - 1750 kg

Towing Capacity:

Not typically specified for this model, designed primarily for passenger use.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (1999 Test) - Adult occupant protection

Active Features

Standard Anti-lock Braking System

Optional Electronic Stability Program

Traction Control:

ASR (Anti-Slip Regulation) often paired with ESP

Passive Features

Airbags:

Front airbags standard. Side airbags and window airbags optional.

Seatbelts:

All seating positions equipped with three-point seatbelts. Pre-tensioners and load limiters for front seats.

Child Seat Anchors:

ISOFIX mounting points for child seats (rear seats).

💡 Technology Features

Infotainment

Head Unit:

Various factory-installed Mercedes-Benz Audio or COMAND systems depending on trim and year. May include cassette, CD player, and optional navigation.

Driver Assistance

Cruise Control:

Optional on most models.

Parking Sensors:

Rear parking sensors became more common in later models or as an option.

Connectivity

Auxiliary Input:

Rarely standard, often requires aftermarket adapter for audio devices.

Bluetooth:

Not available on original models; aftermarket solutions exist.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable, typically every 15,000 km or 1 year, indicated by 'Service A' or 'Service B' on the display (depending on driving conditions).

Air Filter Replacement:

Every 30,000 km or 2 years

Cabin Filter Replacement:

Every 30,000 km or 2 years

Fuel Filter Replacement:

Every 60,000 km (Diesel models); gasoline models typically have lifetime filters or integrated into fuel pump assembly.

Spark Plug Replacement:

Every 60,000 km (A160 gasoline)

Brake Fluid Replacement:

Every 2 years

Fluid Specifications

Engine Oil Capacity A160:

Approx. 5.0 Liters (4.2 US quarts)

Engine Oil Specification A160:

MB Approval 229.1 or 229.3 (e.g., SAE 5W-40 or 10W-40)

Engine Oil Capacity A160 Cdi:

Approx. 5.0 Liters (4.2 US quarts)

Engine Oil Specification A160 Cdi:

MB Approval 229.1 or 229.5 (e.g., SAE 5W-40 Low SAPS recommended for CDI)

Coolant Type:

MB Approved Antifreeze/Coolant, Specification 325.0 (Ethylene Glycol based, typically blue)

Power Steering Fluid:

MB Approved Hydraulic Fluid, Specification 343.0 (Green)

Known Issues

Common Faults A160 Gasoline:

Ignition coil failures, lambda sensor issues, crankshaft position sensor failures, oil leaks from valve cover gasket, premature wear of front suspension bushings.

Common Faults A160 Cdi:

Injector seal leaks, turbocharger issues (over time), glow plug failures, EGR valve clogging, wear on the Autotronic transmission clutch pack (if equipped).

General W168 Issues:

Corrosion on rear wheel arches and sills, failure of the rear door release mechanism, degradation of rubber seals and hoses.

📚 Vehicle History

Brand Heritage

Manufacturer:

DaimlerChrysler AG (Mercedes-Benz brand)

Model Evolution

Introduction Year:

Facelift:

Minor facelift in 2001 with updated styling, improved interior, and revised engine options.

Generation End:

2004 (replaced by W169 A-Class)

Production

Manufacturing Plant:

Rastatt, Germany

Production Volume:

Over 1.1 million units worldwide across its lifecycle.

🏆 Awards & Recognition

Recognitions

Safety Award:

Awarded 4 stars in Euro NCAP crash tests, demonstrating good safety for its class and era.

Innovation Award:

Praised for its innovative safety concept and space efficiency upon launch.

Ratings

Reliability Perception:

Mixed. While Mercedes-Benz build quality is generally high, specific components can be prone to wear, as detailed in the manual's troubleshooting section.