Mercedes W168 A210 1997-2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: A-Class Model Code: W168 Specific Variant: A210 Evolution Codes Product Identifier: Mercedes W168 A210 1997-2004 Workshop Repair Service Manual PDF Download 👋 Introduction Market Position Segment: Compact car, premium segment. Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops, automotive technicians. Competitive Analysis Key Competitors: Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series (Compact). Key Features Vehicle Unique Selling Points: Sandwich floor construction for safety and interior space maximization, innovative 'Sesame' door opening mechanism (on some variants), distinctive styling. Manual Value Proposition: Provides comprehensive technical data and procedures essential for maintaining and repairing the specific A210 Evolution model, enabling cost savings and self-sufficiency. 📋 Manual Details Coverage Areas Covered Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Page Count Estimated Page Count: Extensive (specific number not provided, but typical for workshop manuals of this era, likely 1000+ pages) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of the M166 engine (specific to A210 Evolution variant), including disassembly, assembly, diagnostics, and repair of all internal and external components. Transmission: Details on the manual transmission, automatic transmission (if applicable to A210 Evolution), including clutch, gearbox, differentials, driveshafts, and shift mechanisms. Fuel System: In-depth information on fuel injection systems (Bosch Motronic variants), fuel pumps, injectors, fuel lines, evaporative emission control, and fuel tank. Cooling System: Coverage of radiator, water pump, thermostat, coolant hoses, expansion tank, and fan operation. Exhaust System: Details on exhaust manifold, catalytic converter, mufflers, and exhaust pipes, including emissions control components. Brake System: Complete coverage of front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake lines, master cylinder, and servo. Steering System: Information on power steering rack, pump, fluid, and steering column components. Suspension System: Detailed diagrams and procedures for front and rear suspension, including McPherson struts, control arms, springs, shock absorbers, and anti-roll bars. Electrical System: Extensive coverage of the entire electrical system, including battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, and wiring diagrams. Engine Control Unit ECU: Diagnostic procedures, sensor functions, and actuator testing related to the engine control module. Body And Chassis: Structural information, body panel removal and installation, door mechanisms, glass, and sealing. Climate Control: HVAC system operation, refrigerant, compressor, evaporator, condenser, and controls. Safety Systems: Airbag systems (SRS), seat belt pre-tensioners, and associated sensors and control modules. Procedures Included Maintenance: Scheduled maintenance tasks such as oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacements. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, and common problem identification for all major systems. Repair: Step-by-step instructions for component removal, installation, overhaul, and adjustment for virtually every part of the vehicle. Diagnostics: Detailed diagnostic procedures, including OBD-II (On-Board Diagnostics) scan tool usage, sensor data interpretation, and fault code analysis. Specifications And Tolerances: Precise torque specifications, measurement tolerances, clearances, and alignment data for critical components. Wiring Diagrams: Comprehensive, high-resolution wiring schematics for all electrical systems, including power distribution, grounds, and component connections. Technical Depth Depth: Comprehensive, from basic user maintenance to complex mechanical and electrical component overhauls and diagnostics. Diagnostic Tools Required: Details on specialized Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis/XENTRY) and generic OBD-II scanners, along with their usage. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Compatibility: Compatible with any device capable of opening PDF files (computers, tablets, smartphones). Print Quality Quality: Professional, high-resolution scans suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M166.971 (for A210 Evolution) Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 2.1 liters (2085 cc) Bore X Stroke: 83.0 mm x 96.0 mm Performance Horsepower: 140 PS (138 hp; 103 kW) at 5250 rpm Torque: 205 Nm (151 lb-ft) at 3000 rpm Redline: 6300 rpm (approx.) Fuel System Fuel Injection: Electronic Multi-Point Fuel Injection (MPI), Bosch Motronic ME 2.8 (typical) Fuel Type: Unleaded gasoline (Octane rating 95 RON recommended) Engine Management Ignition System: Distributorless Ignition System (DIS) with individual coil-on-plug or coil packs. Emission Control: Sequential multi-point injection, secondary air injection (on some variants), closed-loop feedback system with oxygen sensors, catalytic converter. 🔧 Transmission Standard Type: 5-speed Manual Transmission (likely) Optional Type: Autotronic (Continuously Variable Transmission - CVT) was available on other W168 models, check specific A210 Evolution documentation for exact availability. Features Clutch: Hydraulically operated single dry plate clutch. Gear Ratios: Specific ratios detailed in the manual for each gear and final drive. Transmission Fluid Spec: Manual: MB 235.10 / MB 235.4 (e.g., SAE 75W-85 GL-4 or GL-5). Automatic/CVT: MB 236.20 (if applicable). 📐 Dimensions Exterior Length:...

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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:

Specific Variant:

A210 Evolution

Codes

Product Identifier:

Mercedes W168 A210 1997-2004 Workshop Repair Service Manual PDF Download

👋 Introduction

Market Position

Segment:

Compact car, premium segment.

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops, automotive technicians.

Competitive Analysis

Key Competitors:

Volkswagen Golf, Ford Focus, Opel Astra, BMW 3 Series (Compact).

Key Features

Vehicle Unique Selling Points:

Sandwich floor construction for safety and interior space maximization, innovative 'Sesame' door opening mechanism (on some variants), distinctive styling.

Manual Value Proposition:

Provides comprehensive technical data and procedures essential for maintaining and repairing the specific A210 Evolution model, enabling cost savings and self-sufficiency.

📋 Manual Details

Coverage Areas

Covered Years:

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

Page Count

Estimated Page Count:

Extensive (specific number not provided, but typical for workshop manuals of this era, likely 1000+ pages)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage of the M166 engine (specific to A210 Evolution variant), including disassembly, assembly, diagnostics, and repair of all internal and external components.

Transmission:

Details on the manual transmission, automatic transmission (if applicable to A210 Evolution), including clutch, gearbox, differentials, driveshafts, and shift mechanisms.

Fuel System:

In-depth information on fuel injection systems (Bosch Motronic variants), fuel pumps, injectors, fuel lines, evaporative emission control, and fuel tank.

Cooling System:

Coverage of radiator, water pump, thermostat, coolant hoses, expansion tank, and fan operation.

Exhaust System:

Details on exhaust manifold, catalytic converter, mufflers, and exhaust pipes, including emissions control components.

Brake System:

Complete coverage of front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake lines, master cylinder, and servo.

Steering System:

Information on power steering rack, pump, fluid, and steering column components.

Suspension System:

Detailed diagrams and procedures for front and rear suspension, including McPherson struts, control arms, springs, shock absorbers, and anti-roll bars.

Electrical System:

Extensive coverage of the entire electrical system, including battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, and wiring diagrams.

Engine Control Unit ECU:

Diagnostic procedures, sensor functions, and actuator testing related to the engine control module.

Body And Chassis:

Structural information, body panel removal and installation, door mechanisms, glass, and sealing.

Climate Control:

HVAC system operation, refrigerant, compressor, evaporator, condenser, and controls.

Safety Systems:

Airbag systems (SRS), seat belt pre-tensioners, and associated sensors and control modules.

Procedures Included

Maintenance:

Scheduled maintenance tasks such as oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacements.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, and common problem identification for all major systems.

Repair:

Step-by-step instructions for component removal, installation, overhaul, and adjustment for virtually every part of the vehicle.

Diagnostics:

Detailed diagnostic procedures, including OBD-II (On-Board Diagnostics) scan tool usage, sensor data interpretation, and fault code analysis.

Specifications And Tolerances:

Precise torque specifications, measurement tolerances, clearances, and alignment data for critical components.

Wiring Diagrams:

Comprehensive, high-resolution wiring schematics for all electrical systems, including power distribution, grounds, and component connections.

Technical Depth

Depth:

Comprehensive, from basic user maintenance to complex mechanical and electrical component overhauls and diagnostics.

Diagnostic Tools Required:

Details on specialized Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis/XENTRY) and generic OBD-II scanners, along with their usage.

Special Tools:

Identification and usage instructions for any specialized tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Compatibility:

Compatible with any device capable of opening PDF files (computers, tablets, smartphones).

Print Quality

Quality:

Professional, high-resolution scans suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M166.971 (for A210 Evolution)

Engine Type:

Inline 4-cylinder, naturally aspirated

Displacement:

2.1 liters (2085 cc)

Bore X Stroke:

83.0 mm x 96.0 mm

Performance

Horsepower:

140 PS (138 hp; 103 kW) at 5250 rpm

Torque:

205 Nm (151 lb-ft) at 3000 rpm

Redline:

6300 rpm (approx.)

Fuel System

Fuel Injection:

Electronic Multi-Point Fuel Injection (MPI), Bosch Motronic ME 2.8 (typical)

Fuel Type:

Unleaded gasoline (Octane rating 95 RON recommended)

Engine Management

Ignition System:

Distributorless Ignition System (DIS) with individual coil-on-plug or coil packs.

Emission Control:

Sequential multi-point injection, secondary air injection (on some variants), closed-loop feedback system with oxygen sensors, catalytic converter.

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (likely)

Optional

Type:

Autotronic (Continuously Variable Transmission - CVT) was available on other W168 models, check specific A210 Evolution documentation for exact availability.

Features

Clutch:

Hydraulically operated single dry plate clutch.

Gear Ratios:

Specific ratios detailed in the manual for each gear and final drive.

Transmission Fluid Spec:

Manual: MB 235.10 / MB 235.4 (e.g., SAE 75W-85 GL-4 or GL-5). Automatic/CVT: MB 236.20 (if applicable).

📐 Dimensions

Exterior

Length:

Approx. 3626 mm (142.8 in) for standard wheelbase

Width:

Approx. 1719 mm (67.7 in)

Height:

Approx. 1575 mm (62.0 in)

Wheelbase:

Approx. 2407 mm (94.8 in)

Ground Clearance:

Approx. 120 mm (4.7 in)

Weights

Curb Weight:

Approx. 1200 - 1250 kg (2646 - 2756 lbs) depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 1700 kg (3748 lbs)

Cargo

Cargo Volume:

Approx. 390 liters (13.8 cu ft) with rear seats up, expandable to over 1100 liters (38.8 cu ft) with seats folded.

🛡️ Safety Features

Ratings

Euroncap Rating:

Initially rated 4 stars for adult occupant protection in 1998 (W168 generation), later revised with slight improvements.

Active Features

Standard Anti-lock Braking System (ABS)

Optional Electronic Stability Program (ESP) on later models or specific trims.

Traction Control:

ASR (Acceleration Slip Regulation) often integrated with ESP.

Passive Features

Airbags:

Front airbags for driver and passenger, optional side airbags.

Seat Belts:

3-point inertia-reel seat belts with belt tensioners and force limiters.

Crash Structure:

Advanced 'sandwich' floor construction designed to slide under obstacles in a frontal collision, protecting occupants in a higher position.

💡 Technology Features

Infotainment

Audio System:

Standard Mercedes-Benz radio/cassette or CD player, with options for upgraded sound systems and navigation.

Display:

Multi-function display in the instrument cluster for vehicle status and trip information.

Driver Assistance

Cruise Control:

Optional cruise control system.

Parking Assistance:

Optional rear parking sensors (Parktronic) on later models.

Connectivity

Phone Integration:

Optional integrated hands-free phone system (early Bluetooth or cradle-based).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (flexible service system - ASSYST).

Air Filter Replacement:

Every 45,000 km (28,000 miles) or 36 months.

Cabin Filter Replacement:

Every 30,000 km (18,600 miles) or 24 months.

Spark Plug Replacement:

Every 60,000 km (37,000 miles) or 48 months (using specified iridium spark plugs).

Brake Fluid Change:

Every 2 years, regardless of mileage.

Coolant Change:

Every 5 years or 100,000 km (62,000 miles).

Fluid Specifications

Engine Oil:

MB-Approval 229.1 or 229.3 (e.g., 0W-30, 5W-30, 5W-40 synthetic).

Engine Oil Capacity:

Approx. 5.5 liters (with filter change).

Coolant:

Mercedes-Benz specification approved coolant (e.g., G48 concentrate mixed 1:1 with distilled water).

Power Steering Fluid:

MB-Approval 236.3 (e.g., hydraulic fluid/ATF type Dexron II/III).

Known Issues

Common Problems:

Potential for premature wear of rear axle bushings, thermostat housing leaks, minor electrical gremlins (especially related to early CAN bus implementations), ignition coil failures, and suspension component wear.

Corrosion:

Can be susceptible to rust in common areas like wheel arches and sill panels, particularly in regions with harsh weather conditions.

📚 Vehicle History

Brand Heritage

Manufacturer:

Daimler AG (Mercedes-Benz)

Model Evolution

Introduction Date:

Facelift:

A facelift occurred in 2001, with styling updates and technical refinements.

A210 Evolution Placement:

The A210 Evolution was a sportier, higher-performance variant introduced later in the W168's lifecycle, often featuring unique styling cues and enhanced engine output.

Production

Production Period:

1997-2004

Manufacturing Locations:

Primarily Rastatt, Germany.

🏆 Awards & Recognition

Recognitions

Safety Awards:

While specific awards for the A210 Evolution are scarce, the W168 generation was recognized for its innovative safety structure, contributing to its Euro NCAP rating.

Ratings

Consumer Reports Reliability:

Reliability ratings varied, with some models exhibiting average or below-average scores for certain components, highlighting the importance of a good service manual for proactive maintenance.