Mercedes W168 A190 1997-2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Internal Chassis Code: W168 Specific Model Variant: A190 Codes Engine Code Typical: M166.990 (though A190 specifically likely uses a variant for its displacement) Model Generation: First Generation (W168) 👋 Introduction Market Position Vehicle Segment Positioning: The W168 A-Class was Mercedes-Benz's entry into the compact hatchback segment, aiming to attract a younger demographic and compete with European rivals. It offered premium build quality and safety features typically found in larger Mercedes-Benz models. Competitive Analysis Primary Competitors: Volkswagen Golf, Ford Focus, BMW 3 Series Compact (E36/5), Audi A3 (8L). Key Features Vehicle Unique Selling Points: Sandwich floor construction for enhanced safety and interior packaging, compact dimensions with surprisingly spacious interior, advanced safety systems for its class, distinctive styling. Manual Value Proposition Manual Benefit For Owner: Empowers owners and technicians with the detailed knowledge required for accurate diagnosis, efficient repair, and proper maintenance, ensuring the longevity and optimal performance of the Mercedes-Benz W168 A190. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for Mercedes-Benz W168 A190 Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive factory-level manuals) Manual Type Manual Classification: Service and Repair Manual Language Manual Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel injection system, ignition system, cooling system, lubrication system, exhaust system, engine control unit (ECU) and sensors. Transmission Systems: Manual and automatic transmission servicing, repair, clutch replacement, gearbox overhaul, torque converter, shift mechanisms, transmission control unit (TCU). Chassis Systems: Suspension (front and rear), steering system (rack and pinion, power steering), brakes (hydraulic system, ABS, brake pads, discs, calipers, bleeding), wheels and tires, chassis lubrication. Electrical Systems: Wiring diagrams, battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, body control module (BCM), comfort electronics, instrument cluster, infotainment system wiring. Body And Trim: Body panel removal/installation, door mechanisms, interior trim, seats, glass, sunroof, bumpers, seals, paint repair (guidelines). Procedures Included Maintenance Procedures: Routine maintenance tasks such as oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-ups, brake fluid flush, coolant flush, belt inspections and replacement. Repair Procedures: Detailed step-by-step instructions for component removal, repair, and reinstallation for all major systems. Includes engine overhauls, transmission rebuilds, suspension component replacement, brake system repairs, electrical troubleshooting and component replacement. Troubleshooting Diagnostics: Fault finding guides, diagnostic trouble codes (DTCs) interpretation, common problem diagnosis, wiring diagram analysis for electrical faults, mechanical troubleshooting. Technical Specifications Data: Torque specifications for all fasteners, fluid capacities, fluid types and grades, component clearances, engine timing procedures, electrical system voltages and resistances. Technical Depth Depth Of Information: Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY mechanics. Covers detailed component disassembly, overhaul, and reassembly. 📊 Manual Specifications File Format PDF Quality And Features: High-resolution PDF, often searchable text, allowing for quick navigation and information retrieval. May include hyperlinked sections for ease of use. Printable pages. Print Quality Digital Reproduction Quality: Designed for clear digital viewing and printing. Diagrams, illustrations, and text are rendered with clarity. Binding Type Digital Format Binding: N/A (PDF format) Paper Type Digital Format Paper Reference: N/A (PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, Naturally Aspirated Displacement: 1.9 Liters (1900 cc) Performance Horsepower Approximate: Approximately 125 hp (92 kW) at around 5500 rpm Torque Approximate: Approximately 175 Nm (129 lb-ft) at around 4200 rpm Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI), likely Bosch Motronic or similar. Fuel Grade Recommendation: Premium Unleaded Gasoline (91 Octane or higher) Engine Management Engine Control Unit Type: Integrated engine and transmission control, specific Bosch or Siemens ECU. Engine Layout Engine Orientation: Transverse, Front-Wheel Drive 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission Optional Optional Transmission Type: 5-Speed Automatic Transmission (often referred to as AUTOSTAR) Features Transmission Fluid Type: Specific Mercedes-Benz Automatic Transmission Fluid (e.g., MB 236.10 or equivalent for automatic, GL-4 for manual) 📐 Dimensions Exterior Length Approximate: 3626 mm (142.8 in) Width Approximate: 1720 mm (67.7 in) Height Approximate: 1591 mm (62.6 in) Weights Curb Weight Approximate: 1180 - 1250 kg (2600 - 2750 lbs) depending on configuration Cargo Cargo Volume Rear Seats Up Approximate: 390 Liters (13.8 cu ft) Cargo Volume Rear Seats Down Approximate: 1170 Liters (41.3 cu ft) 🛡️ Safety Features Ratings Euro Ncap Rating: Achieved a strong 4-star Euro NCAP rating in its initial tests, notable for its class at the time. Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (ASR). Passive Features Passive Safety Features: Front airbags, side airbags (optional/standard depending on trim), front and rear crumple zones, reinforced passenger cell, seatbelt pretensioners. Structural Features Sandwich Platform Safety Benefit: The 'sandwich' floor design allowed the engine and drivetrain to slide...
M166.990 (though A190 specifically likely uses a variant for its displacement)
Model Generation:
First Generation (W168)
👋 Introduction
Market Position
Vehicle Segment Positioning:
The W168 A-Class was Mercedes-Benz's entry into the compact hatchback segment, aiming to attract a younger demographic and compete with European rivals. It offered premium build quality and safety features typically found in larger Mercedes-Benz models.
Competitive Analysis
Primary Competitors:
Volkswagen Golf, Ford Focus, BMW 3 Series Compact (E36/5), Audi A3 (8L).
Key Features
Vehicle Unique Selling Points:
Sandwich floor construction for enhanced safety and interior packaging, compact dimensions with surprisingly spacious interior, advanced safety systems for its class, distinctive styling.
Manual Value Proposition
Manual Benefit For Owner:
Empowers owners and technicians with the detailed knowledge required for accurate diagnosis, efficient repair, and proper maintenance, ensuring the longevity and optimal performance of the Mercedes-Benz W168 A190.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair for Mercedes-Benz W168 A190
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive factory-level manuals)
Manual Type
Manual Classification:
Service and Repair Manual
Language
Manual Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel injection system, ignition system, cooling system, lubrication system, exhaust system, engine control unit (ECU) and sensors.
Transmission Systems:
Manual and automatic transmission servicing, repair, clutch replacement, gearbox overhaul, torque converter, shift mechanisms, transmission control unit (TCU).
Chassis Systems:
Suspension (front and rear), steering system (rack and pinion, power steering), brakes (hydraulic system, ABS, brake pads, discs, calipers, bleeding), wheels and tires, chassis lubrication.
Electrical Systems:
Wiring diagrams, battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, body control module (BCM), comfort electronics, instrument cluster, infotainment system wiring.
Body And Trim:
Body panel removal/installation, door mechanisms, interior trim, seats, glass, sunroof, bumpers, seals, paint repair (guidelines).
Procedures Included
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-ups, brake fluid flush, coolant flush, belt inspections and replacement.
Repair Procedures:
Detailed step-by-step instructions for component removal, repair, and reinstallation for all major systems. Includes engine overhauls, transmission rebuilds, suspension component replacement, brake system repairs, electrical troubleshooting and component replacement.
Troubleshooting Diagnostics:
Fault finding guides, diagnostic trouble codes (DTCs) interpretation, common problem diagnosis, wiring diagram analysis for electrical faults, mechanical troubleshooting.
Technical Specifications Data:
Torque specifications for all fasteners, fluid capacities, fluid types and grades, component clearances, engine timing procedures, electrical system voltages and resistances.
Technical Depth
Depth Of Information:
Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY mechanics. Covers detailed component disassembly, overhaul, and reassembly.
📊 Manual Specifications
File Format
PDF Quality And Features:
High-resolution PDF, often searchable text, allowing for quick navigation and information retrieval. May include hyperlinked sections for ease of use. Printable pages.
Print Quality
Digital Reproduction Quality:
Designed for clear digital viewing and printing. Diagrams, illustrations, and text are rendered with clarity.
Binding Type
Digital Format Binding:
N/A (PDF format)
Paper Type
Digital Format Paper Reference:
N/A (PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, Naturally Aspirated
Displacement:
1.9 Liters (1900 cc)
Performance
Horsepower Approximate:
Approximately 125 hp (92 kW) at around 5500 rpm
Torque Approximate:
Approximately 175 Nm (129 lb-ft) at around 4200 rpm
Fuel System
Fuel Delivery System:
Electronic Fuel Injection (EFI), likely Bosch Motronic or similar.
Fuel Grade Recommendation:
Premium Unleaded Gasoline (91 Octane or higher)
Engine Management
Engine Control Unit Type:
Integrated engine and transmission control, specific Bosch or Siemens ECU.
Engine Layout
Engine Orientation:
Transverse, Front-Wheel Drive
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual Transmission
Optional
Optional Transmission Type:
5-Speed Automatic Transmission (often referred to as AUTOSTAR)
Features
Transmission Fluid Type:
Specific Mercedes-Benz Automatic Transmission Fluid (e.g., MB 236.10 or equivalent for automatic, GL-4 for manual)
📐 Dimensions
Exterior
Length Approximate:
3626 mm (142.8 in)
Width Approximate:
1720 mm (67.7 in)
Height Approximate:
1591 mm (62.6 in)
Weights
Curb Weight Approximate:
1180 - 1250 kg (2600 - 2750 lbs) depending on configuration
Cargo
Cargo Volume Rear Seats Up Approximate:
390 Liters (13.8 cu ft)
Cargo Volume Rear Seats Down Approximate:
1170 Liters (41.3 cu ft)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Achieved a strong 4-star Euro NCAP rating in its initial tests, notable for its class at the time.
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (ASR).
Passive Features
Passive Safety Features:
Front airbags, side airbags (optional/standard depending on trim), front and rear crumple zones, reinforced passenger cell, seatbelt pretensioners.
Structural Features
Sandwich Platform Safety Benefit:
The 'sandwich' floor design allowed the engine and drivetrain to slide underneath the passenger compartment in a severe frontal impact, enhancing occupant protection.
💡 Technology Features
Infotainment
Infotainment System Features:
Basic audio systems with CD/radio, optional navigation systems (APS 30), and climate control. Limited by the era of its production.
Driver Assistance
Driver Assistance Features:
Primary focus on safety systems like ABS and ESP. Cruise control was often an optional extra.
Connectivity
Connectivity Options:
Minimal by modern standards. May have provisions for early mobile phone integration or CD changers.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 1 year, whichever comes first (dependent on service indicator system and oil type used).
Major Service Interval:
Intervals for spark plug replacement, brake fluid, coolant, and other major items vary but are typically around 60,000 km (37,000 miles) or 3-4 years.
Fluid Specifications
Engine Oil Specification:
SAE 0W-30 or 5W-40, meeting MB 229.5 or MB 229.3 specifications. Consult manual for exact approval codes.
Coolant Specification:
Mercedes-Benz approved G48 antifreeze/coolant concentrate (blue-green) mixed with deionized water (50/50 ratio).
Brake Fluid Specification:
DOT 4, ideally a low-viscosity variant (e.g., DOT 4 PLUS or DOT 4 LV) meeting MB 331.0.
Known Issues
Common Wear And Tear Items:
Front control arm bushings, rear shock absorbers, exhaust system components (muffler, catalytic converter), ignition coils, mass air flow (MAF) sensor.
Electrical Gremlins:
Occasional issues with window regulators, central locking systems, and corrosion on electrical connectors can occur due to age and environmental factors.
Powertrain Considerations:
Timing chain tensioners (on some engine variants, though M166 is generally robust), clutch wear (on manual transmissions), transmission control module issues (on automatics).
📚 Vehicle History
Brand Heritage
Mercedes Benz Heritage In Compact Segment:
The W168 represented Mercedes-Benz's first serious foray into the subcompact segment, challenging its traditional image of luxury sedans and SUVs. It aimed to broaden the brand's appeal.
Model Evolution
W168 Facelift And Updates:
Received a significant facelift in 2001, with updated styling, improved interior materials, revised suspension, and new engine options. The A190 was available both pre- and post-facelift.
Production
Production Period:
1997 - 2004
Manufacturing Locations:
Primarily manufactured at the Mercedes-Benz plant in Rastatt, Germany, and subsequently in Kecskemét, Hungary.
🏆 Awards & Recognition
Recognitions
Safety Awards Recognition:
The W168 was recognized for its innovative safety design, particularly its 'sandwich' floor concept, which contributed to its strong Euro NCAP performance.
Ratings
Reliability Rankings Era:
While Mercedes-Benz vehicles are generally known for quality, the W168, being an early foray into the compact segment, had mixed reliability reports compared to more established models in its class, especially as it aged. Detailed service is crucial.
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