🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

W460

Model Variant:

230G

Engine Code:

M123 (likely, as a placeholder for the 2.3L petrol engine)

👋 Introduction

Market Segment:

Luxury Off-Road Vehicle / Utility Vehicle

Target Demographic:

Individuals seeking robust, durable, and capable off-road vehicles with a luxury pedigree; also used by military and utility organizations.

Primary Competitors:

Range Rover Classic, Land Rover Defender (early models), Toyota Land Cruiser (early models).

Off Road Capability:

Ladder frame chassis, solid axles with long-travel suspension, locking differentials (optional on some models), robust 4WD system providing exceptional articulation and traction.

Durability And Longevity:

Renowned for its over-engineered construction, designed for extreme conditions and extended service life.

Iconic Design:

Timeless, utilitarian design characterized by its boxy, angular shape and functional aesthetics.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Cooling System, Exhaust System, Ignition System, Clutch, Transmission (Manual/Automatic), Transfer Case, Drive Axles, Suspension, Steering, Brakes (Front Disc/Rear Drum), Electrical System, Lighting, Bodywork, Interior Trim, Maintenance Procedures, Troubleshooting, Diagnostics, Specifications, Torque Values, Wiring Diagrams.

Estimated Page Count:

500-800 (typical for comprehensive W460 service manuals)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, and reassembly of the 2.3L petrol engine, including cylinder head, block, pistons, crankshaft, camshaft, and valve train.

Fuel And Emission Control:

Carburetor service (likely Solex or Zenith), fuel pump, fuel lines, fuel filter replacement, emissions control systems (if applicable to the 230G).

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch, flush and refill procedures.

Ignition System:

Distributor, ignition coil, spark plugs, ignition timing adjustment, spark plug wires.

Drivetrain Manual Transmission:

Clutch replacement, manual transmission overhaul and repair, gear shifting mechanisms.

Drivetrain Transfer Case:

Transfer case operation, maintenance, and repair, including 4WD engagement and gear reduction.

Drivetrain Axles And Differentials:

Front and rear axle assembly, differential maintenance and repair, locking differentials (if equipped).

Suspension System:

Front and rear suspension components, shock absorbers, springs, bushings, articulation of the robust W460 suspension.

Steering System:

Steering gearbox, steering linkage, power steering pump and system maintenance.

Brake System:

Front disc brake service (pads, rotors, calipers), rear drum brake service (shoes, drums, wheel cylinders), brake fluid replacement, bleeding procedures.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams for various circuits.

Lighting And Accessories:

Headlights, taillights, turn signals, interior lighting, horn, wipers, washers.

Body And Chassis:

Body panel removal and installation, door mechanisms, hinges, latches, glass replacement, rust prevention and repair guidance.

Interior Trim And Upholstery:

Dashboard removal, seat adjustments, interior paneling, carpeting.

Preventive Maintenance:

Oil changes, filter replacements (oil, fuel, air), spark plug replacement, coolant flush, brake fluid flush, lubrication points.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common and uncommon issues, including symptom analysis and component testing.

Component Repair And Rebuild:

Detailed instructions for the overhaul and repair of all major mechanical and electrical components.

Adjustment Procedures:

Setting ignition timing, carburetor adjustments, valve clearance adjustments, brake adjustments.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners throughout the vehicle.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, aiding in troubleshooting and repairs.

Diagnostic Capabilities:

Advanced diagnostic procedures, including component testing using multimeter and specialized tools (where applicable for the era).

Rebuild Scope:

Full engine, transmission, and differential rebuild procedures.

Special Tools Requirements:

Identification of special tools required for specific repair procedures, often referencing Mercedes-Benz specific tooling.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (typical for well-scanned PDFs)

Printable:

Yes

Image Quality:

High-resolution scans of original manual pages, including diagrams and photographs.

Print Quality:

N/A (Digital PDF format)

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Inline-4 Cylinder, Petrol

Displacement:

2.3 Liters (2299 cc)

Bore X Stroke:

Approx. 93.0 mm x 83.6 mm (typical for M123 family)

Compression Ratio:

Approx. 8.3:1 to 8.7:1 (model dependent)

Valvetrain:

SOHC (Single Overhead Camshaft), 8 Valves

Horsepower Net:

Approx. 102-125 PS (75-92 kW) at 4800-5200 rpm (varies by market and specific engine tune)

Torque Net:

Approx. 170-190 Nm (125-140 lb-ft) at 2500-3000 rpm (varies by market and specific engine tune)

Fuel Delivery:

Carburetor (e.g., Solex 32/32 DIDTA or similar twin-choke)

Fuel Type:

Unleaded Gasoline (Octane rating typically 91 RON or higher)

Fuel Tank Capacity:

Approx. 75 liters (main tank) + optional auxiliary tank

🔧 Transmission

Type:

4-speed Manual Transmission

Type:

3-speed Automatic Transmission (e.g., Mercedes-Benz 722.3)

Transfer Case:

2-speed transfer case with selectable 4WD and low-range gearing.

Differential Locks:

Center differential lock (standard on W460) and optional front and rear axle locking differentials.

📐 Dimensions

Wheelbase:

Approx. 2400 mm (short wheelbase), 2850 mm (long wheelbase)

Length:

Approx. 4235 mm (short) / 4635 mm (long)

Width:

Approx. 1760 mm

Height:

Approx. 1965 mm

Ground Clearance:

Approx. 220 mm (unladen)

Curb Weight:

Approx. 1900-2100 kg (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 2700-3000 kg

🛡️ Safety Features

Crash Test Performance:

As a vehicle from the early 1980s, formal crash test ratings (like NCAP) were not as prevalent or standardized. However, its robust construction provided good occupant protection for its era.

Braking System:

Four-wheel disc brakes were introduced on later W460 models, but the 230G often featured front discs and rear drums.

Four Wheel Drive:

Permanent 4WD with center differential lock enhances traction and stability.

Chassis Construction:

Heavy-duty ladder frame chassis offering significant structural integrity.

Seatbelts:

Standard three-point seatbelts in the front, lap belts in the rear (configuration dependent).

💡 Technology Features

Radio System:

Typically basic AM/FM radio with cassette player. Aftermarket upgrades are common.

ABS:

Anti-lock Braking System (ABS) became available on later W460 models, but may not be standard on all 230G variants.

Vintage Design:

Technology is focused on mechanical reliability rather than modern electronic connectivity. Features are largely mechanical controls.

🔧 Maintenance

Oil Change:

Every 5,000 - 7,500 km or 6-12 months (whichever comes first), using premium oil.

Air Filter Replacement:

Every 15,000 - 20,000 km or as needed in dusty conditions.

Fuel Filter Replacement:

Every 10,000 - 15,000 km.

Spark Plug Replacement:

Every 20,000 - 30,000 km (platinum or multi-electrode plugs may extend this).

Coolant Flush And Replacement:

Every 24-36 months or 40,000-60,000 km.

Brake Fluid Flush And Replacement:

Every 24 months, regardless of mileage.

Engine Oil Type:

API SG or higher; SAE 10W-40 or 15W-40 (depending on climate). Consult specific MB technical bulletin for optimal selection.

Engine Oil Capacity:

Approx. 5.0 - 5.5 liters (with filter change)

Coolant Type:

Mercedes-Benz approved coolant (typically silicate-free, ethylene glycol based) mixed 50/50 with distilled water.

Transmission Fluid Manual:

API GL-4 SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

MB Specification 236.1 or 236.3 ATF (e.g., Dexron II/III compatible).

Transfer Case Fluid:

API GL-4 SAE 80W-90 gear oil.

Differential Fluid:

API GL-5 SAE 80W-90 gear oil (or as specified by MB for limited-slip differentials if equipped).

Brake Fluid Type:

DOT 3 or DOT 4, meeting Mercedes-Benz specifications.

Rust And Corrosion:

Prone to rust, especially in the lower body panels, wheel arches, and undercarriage, due to its age and off-road usage. Regular inspection and undercoating are crucial.

Carburetor Issues:

Carburetors can become gummed up or require adjustments over time, leading to rough idling, poor starting, or fuel delivery problems.

Suspension Bushings:

Rubber bushings in the suspension and steering can degrade over time, leading to play, noise, and compromised handling.

Exhaust Manifold Cracks:

Some M123 engines are known to develop cracks in the exhaust manifold due to thermal stress.

Cooling System Leaks:

Aging hoses, radiator, and water pump can lead to coolant leaks.

📚 Vehicle History

Origins:

Mercedes-Benz has a long history of producing robust and reliable vehicles for various applications, including military and off-road use.

Development Brief:

Developed in the 1970s as a versatile off-road and utility vehicle for military and civilian markets, emphasizing durability and cross-country capability.

W460 Generation:

The W460 was the first generation of the G-Wagen, produced from 1979 to 1993. The 230G was one of the initial petrol variants.

Production Period W460:

1979 - 1993

Manufacturing Locations:

Graz, Austria (by Magna Steyr, under contract for Mercedes-Benz).

🏆 Awards & Recognition

Off Road Acclaim:

Consistently recognized as one of the most capable and rugged off-road vehicles ever produced, earning a cult following among enthusiasts and off-roaders.

Military Service:

Widely adopted by military forces worldwide due to its durability, reliability, and off-road performance.