Mercedes Benz G wagen 460 230G Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Model Variant: 230 GE Codes Engine Code Primary: M102.980 Production Era Code: W460 Series (1979-1993) 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 422627

Tags: 230G Car Cars G wagen 460 Mercedes Mercedes Benz Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

Model Variant:

230 GE

Codes

Engine Code Primary:

M102.980

Production Era Code:

W460 Series (1979-1993)

👋 Introduction

Market Position

Vehicle Segment:

Off-road Vehicle / Luxury SUV

Original Intent:

Developed for military and off-road use, later evolved into a luxury icon.

Competitive Analysis

Competitors Era:

Land Rover Defender, Toyota Land Cruiser, Jeep CJ/Wrangler (though positioned higher in luxury).

Key Features

Off Road Capability:

Robust ladder frame chassis, solid front and rear axles, selectable four-wheel drive, differential locks.

Durability:

Built with extremely durable components, designed for extreme conditions and longevity.

Iconic Design:

Timeless, utilitarian, and instantly recognizable squared-off design.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English (Assumed, common for official manuals, confirm with seller)

Format:

Page Count

Estimated Page Count:

1000+ pages (Typical for comprehensive workshop manuals of this era)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnosis, repair, tuning, component specifics for M102 gasoline engines.

Fuel System:

Bosch K-Jetronic fuel injection system, fuel pump, injectors, pressure regulators, troubleshooting.

Cooling System:

Radiator, water pump, thermostat, coolant types, flush and fill procedures, fan clutch diagnosis.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable for market), muffler, pipe routing, leak detection.

Transmission:

Manual and Automatic transmission overhaul, shifting mechanisms, clutch operation, fluid specifications, torque converter service.

Drivetrain:

Transfer case, locking differentials (if equipped), front and rear axle assemblies, driveshafts, U-joints, bearing service.

Suspension:

Front and rear suspension components, springs, shock absorbers, bushings, steering linkage, alignment procedures.

Steering:

Power steering system, pump, gearbox, tie rods, steering column, universal joints, troubleshooting.

Brakes:

Front and rear disc/drum brakes, brake calipers, master cylinder, brake booster, hydraulic lines, parking brake system, ABS (if equipped).

Electrical System:

Battery, alternator, starter motor, ignition system, lighting, fuses, relays, wiring diagrams, diagnostic codes.

Body And Chassis:

Frame construction, body panel removal/installation, door mechanisms, glass, seals, rust prevention, underbody protection.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant, diagnosis, repair.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug service, belt inspection and replacement, greasing points.

Troubleshooting:

Diagnostic charts, common fault finding, symptom-based problem solving, electrical system diagnostics.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Overhaul:

Complete engine rebuild, transmission rebuild, differential overhaul, suspension component replacement.

Diagnostics:

Fault code interpretation, live data analysis (for era appropriate systems), component testing procedures.

Adjustment:

Valve adjustments, ignition timing, carburetor/throttle body adjustments, clutch adjustment, brake adjustments.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Technical Depth

Depth Level:

Professional Technician Level - Assumes prior mechanical knowledge and tool familiarity.

Diagnostic Tools:

Guidance on using basic automotive tools, multimeters, and potentially early diagnostic equipment.

Torque Specifications:

Detailed torque values for all fasteners, crucial for engine and chassis work.

Special Tools:

Identification and usage of Mercedes-Benz specific or equivalent special tools for certain procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchable Text:

Likely searchable if scanned professionally; confirmation recommended.

Print Quality

Image Resolution:

High resolution for diagrams and illustrations, assuming official or high-quality scan.

Clarity:

Clear, legible text and diagrams essential for accurate repairs.

Binding Type

Binding Format:

N/A (Digital PDF)

Paper Type

Paper Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

2.3 Liters (2299 cc)

Bore X Stroke:

93.7 mm x 83.2 mm

Compression Ratio:

8.3:1 (Typical for M102.980)

Fuel Delivery:

Bosch K-Jetronic CIS (Continuous Injection System)

Performance

Horsepower Approx:

125 PS (92 kW) at 5,000 rpm

Torque Approx:

190 Nm (140 lb-ft) at 3,500 rpm

Fuel System

Fuel Type:

Unleaded Gasoline (RON 91+)

Fuel Tank Capacity:

75 Liters (Main) + Optional Auxiliary Tank

🔧 Transmission

Standard

Transmission Type:

4-Speed Manual Transmission (Getrag)

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (Mercedes-Benz 722.3)

Features

Drivetrain Configuration:

Part-time 4WD with optional front axle lock and rear axle lock

Gear Ratios Manual Approx:

1st: 4.02, 2nd: 2.57, 3rd: 1.58, 4th: 1.00, Reverse: 3.74

Transfer Case Gear Ratios:

High Range: 1.00, Low Range: 2.00 (approx.)

Transmission Fluid Type:

API GL-4 (Manual), Dexron III (Automatic) - Verify specific manual requirements.

📐 Dimensions

Exterior

Wheelbase:

2850 mm (Standard 460 chassis)

Length:

4,057 mm (Short Wheelbase SWB variant)

Width:

1,760 mm

Height:

1,950 mm

Ground Clearance:

Approx. 210-240 mm (depending on tire size)

Weights

Curb Weight Approx:

1,900 - 2,100 kg (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 2,800 kg

Towing Capacity Approx:

3,500 kg

Wheels And Tires

Wheel Bolt Pattern:

5x112 mm

Standard Tire Size:

205 R16 or 235/75 R15

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not formally rated by modern standards (e.g., NHTSA, Euro NCAP) due to era of design.

Active Features

Active Safety:

Four-wheel drive, lockable differentials (optional).

Passive Features

Passive Safety:

Robust chassis, seat belts, robust body structure.

💡 Technology Features

Infotainment

Infotainment System Era:

Basic analog radio, optional cassette player, simple climate controls. No digital displays or advanced connectivity.

Driver Assistance

Driver Assistance Features:

Limited to effective 4WD system and locking differentials. No electronic driver aids like ABS (on early models) or traction control.

Connectivity

Connectivity Features:

None by modern standards; basic antenna for radio.

🔧 Maintenance

Service Intervals

Oil Change Interval Engine:

Every 10,000 - 15,000 km or 12 months (check manual for exact specification and severe duty).

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 20,000 - 30,000 km or as needed based on operating conditions.

Spark Plug Replacement:

Every 30,000 - 40,000 km (check specific plug type and manual).

Coolant Flush:

Every 2-3 years or 40,000-60,000 km.

Fluid Specifications

Engine Oil Specification:

API SG/SH, SAE 15W-40 or 10W-40 (check manual for specific ambient temperature recommendations).

Engine Oil Capacity:

Approx. 6.5 Liters (with filter change)

Coolant Specification:

MB Approved Antifreeze/Coolant Concentrate (e.g., G48, Z) mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 4

Known Issues

Common Wear Items:

U-joints, bushings (suspension and steering), brake lines, fuel pump, vacuum leaks (K-Jetronic), rust (especially in common areas like fender flares, rear corners, tailgate).

Electrical Gremlins:

Corrosion in connectors, aging wiring insulation can lead to intermittent faults.

K Jetronic Issues:

Can be sensitive to vacuum leaks, faulty fuel distributor, or incorrect mixture settings, leading to rough running or poor performance.

📚 Vehicle History

Brand Heritage

Mercedes Benz Heritage:

Long history of engineering excellence, luxury vehicles, and commercial vehicles. G-Wagen was a distinct foray into robust off-road capability.

Model Evolution

G Wagen Origins:

Conceived in the late 1970s, initially for military and utility purposes. The W460 was the first generation.

W460 Variants:

Available in short (SWB), long (LWB) wheelbase, convertible, and panel van configurations. Engine options included various petrol (like 230 GE) and diesel engines.

Production

Production Period:

1979-1993 (W460 Series)

Manufacturing Location:

Graz, Austria (Steyr-Daimler-Puch AG, now Magna Steyr)

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

Consistently recognized for unparalleled off-road capability and durability by automotive journalists and enthusiasts.

Ratings

Longevity Reputation:

High reputation for long-term durability and ability to maintain capability with proper maintenance.

Certifications

Design Award Legacy:

While specific design awards might not be documented for this era, its iconic status and lasting design are a testament to its influence.