🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Class

Model Code:

W463

Year:

1990

👋 Introduction

Positioning:

Premium, robust, off-road capable luxury SUV.

Competitors:

Land Rover Defender, Toyota Land Cruiser, Jeep Wrangler (historically, though G-Class positioned higher).

Longevity:

Known for its exceptional durability and off-road prowess, the G-Class has a long production run with minimal fundamental changes.

Engineering:

Body-on-frame construction, three independently locking differentials, robust suspension designed for extreme conditions.

Utility:

Provides direct access to OEM-level repair information, empowering owners and independent mechanics.

Efficiency:

Saves time and money by enabling owners to perform their own maintenance and repairs, avoiding dealership labor costs.

📋 Manual Details

Primary Coverage:

Service and Repair

Scope:

All Models & All Repairs A-Z

Estimated Page Count:

High (Detailed Factory Manual, exact count not specified but implied to be comprehensive)

Type:

Factory Service Manual / Repair Manual

Language:

English

Digital Format:

PDF

Digital Requirements:

Adobe PDF Reader, Winzip (Free)

Digital Compatibility:

Windows (Vista 32/64, XP, ME, 98, NT, 2000), Mac

📖 Manual Coverage

Powertrain:

Engine, Fuel Service Specifications, Emission Control, Intake Exhaust Cooling, Lube, Ignition Starting Charging, Auto Transmission, Clutch, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle Suspension

Chassis:

Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering

Electrical And Body:

Air Condition, Suppl Restraint System, Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/ Door, Exterior & Interior, Electrical, Multiplex/Can Communication

Maintenance:

Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication

Diagnostics:

Troubleshooting Guides, Fault Code Interpretation (Implied by 'Diagnose')

Repair:

Step-by-step instructions for all mechanical and electrical components

Technical Data:

Specifications, Torque Values, Clearances, Alignment Data

Depth:

Factory-level detail for technicians, covering basic maintenance to complex rebuilds and diagnostics.

Visuals:

Diagrams, Illustrations, Wiring Schematics

📊 Manual Specifications

Type:

PDF

Searchability:

Implied searchable text for ease of use

Printability:

All pages printable, with option to enlarge images

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Details vary for 1990 G-Class, likely includes naturally aspirated gasoline and diesel variants. Common for the W463 generation would be inline-6 gasoline (e.g., M103) or diesel (e.g., OM602).

Displacement Gasoline Example:

3.0L or 3.2L Inline-6 (M103 family)

Displacement Diesel Example:

2.5L or 2.9L Inline-5 Diesel (OM602 family)

Horsepower Range Typical:

Approx. 115-160 hp (depending on engine variant)

Torque Range Typical:

Approx. 160-220 lb-ft (depending on engine variant)

Fuel Delivery:

Fuel Injection (Bosch KE-Jetronic or similar electronic injection systems for gasoline; indirect injection for diesel).

Cooling Type:

Water-cooled, pressurized system with fan.

Oil Type Specification:

Manual will specify MB 229.1 or similar, typically 10W-40 or 15W-40 for diesel, and 10W-30 or 10W-40 for gasoline.

🔧 Transmission

Transmission Type:

Likely 4-speed Automatic (e.g., 722.4) or 5-speed Manual Transmission.

Transmission Type Optional:

Depending on market and specific engine, both automatic and manual options were available.

Gear Ratios:

Detailed gear ratios for both manual and automatic transmissions will be provided in the manual.

Transfer Case:

Integral part of the drivetrain, featuring a 2-speed transfer case with center differential lock for enhanced off-road capability.

Automatic Transmission Fluid:

Likely requires Dexron III or MB 236.1 specification fluid.

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, viscosity grade to be specified.

📐 Dimensions

Wheelbase:

Approx. 2850 mm (112.2 in) for standard wheelbase.

Length:

Approx. 4210 mm (165.7 in) for standard wheelbase.

Width:

Approx. 1760 mm (69.3 in).

Height:

Approx. 1931 mm (76.0 in).

Curb Weight:

Approx. 2000-2200 kg (4400-4850 lbs), depending on configuration.

Gross Vehicle Weight Rating:

Typically around 2800-3000 kg (6170-6610 lbs).

Towing Capacity:

Up to 3500 kg (7716 lbs) is common for the G-Class.

🛡️ Safety Features

Crash Test Ratings:

While formal crash test ratings in the modern sense were less prevalent for 1990 vehicles, the G-Class's robust construction provided inherent safety.

Braking System:

Four-wheel disc brakes, often with ABS (Anti-lock Braking System) becoming standard or optional.

Traction Control:

Locking differentials are a key active safety/off-road feature.

Body Structure:

Reinforced chassis and body structure designed for durability and occupant protection.

Seat Belts:

Standard seat belts; manual will detail proper usage and maintenance.

Supplemental Restraint System:

While airbags were not universally standard on the 1990 model, their inclusion (or absence and potential retrofit) would be detailed if applicable.

💡 Technology Features

Audio System:

Original systems would have been basic AM/FM radio with cassette player, potentially with upgraded speakers. Manual will cover removal and replacement procedures.

ABS:

Anti-lock Braking System (ABS) was an available or standard feature depending on the exact configuration, details of its operation and servicing are in the manual.

Cruise Control:

Cruise control systems were common, and the manual will detail its operation, diagnosis, and repair.

Multiplex Can Communication:

The mention of 'Multiplex/CAN Communication' suggests some early forms of networked electronics, and the manual will provide schematics for these systems.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 miles (8,000-16,000 km) or annually, depending on driving conditions. Exact intervals provided in manual.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on operating environment.

Spark Plug Replacement:

For gasoline engines, typically every 30,000-60,000 miles (48,000-96,000 km), manual will specify type and interval.

Coolant Type:

Mercedes-Benz approved coolant (e.g., G48 or similar ethylene glycol-based antifreeze/coolant).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Hydraulic fluid specified by Mercedes-Benz, often Dexron II/III or a specific MB fluid.

Common Wear Items:

Ball joints, tie rod ends, wheel bearings, differential seals, transfer case seals, vacuum lines (age-related degradation).

Electrical Systems:

Aging wiring harnesses, faulty relays, and specific sensor failures can occur with age. The manual's wiring diagrams are crucial here.

Rust Corrosion:

While generally robust, areas prone to rust include fender flares, door bottoms, and tailgate due to environmental exposure and design.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz is renowned for engineering excellence, luxury, and durability, a reputation built over decades with iconic vehicles.

W460 To W463 Transition:

The W463, introduced in 1989 for the 1990 model year, represented a significant evolution from the W460, offering more comfort, improved on-road manners, and modern features while retaining its core off-road capability.

Manufacturing Location:

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

Original Purpose:

Originally developed as a military vehicle, its civilian variants quickly gained popularity for their go-anywhere capability and ruggedness.

🏆 Awards & Recognition

Off Road Acclaim:

The G-Class is universally recognized for its superior off-road capabilities, often considered one of the most capable production vehicles ever made.

Longevity Award:

The sustained production and minimal fundamental changes over its lifespan can be seen as a testament to its successful original design.