Vehicle Segment:
Luxury SUV / Off-Road Vehicle
Target Audience:
Owners seeking to maintain and repair their G-Class vehicles, professional mechanics, enthusiasts
Manual Value Proposition:
Provides comprehensive, factory-level repair information, enabling DIY repairs and reducing reliance on expensive dealership services. Offers a complete A-Z coverage.
Manual Layout:
Step-by-step instructions with detailed exploded views and diagrams.
Accessibility:
Instant download for immediate access on PC, tablet, or laptop.
Model Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Model Variants Covered:
All G-Class models (e.g., G300, G320, G350, G350TD, G400, G500, G550 variants as applicable within the specified years)
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive workshop manuals of this era and vehicle complexity)
Manual Classification:
Factory-Style Workshop Manual / Service and Repair Manual
Coverage Scope:
Comprehensive 'A-Z' coverage for all models and all repairs.
Engine Systems:
Engine removal/installation, fuel system (injection/carburetion), lubrication, cooling, combustion, exhaust, ignition, emission control
Transmission Drivetrain:
Gearbox (manual/automatic), clutch, transfer case, differentials, drive shafts, axles
Chassis Suspension Steering:
Frame, front axle, rear axle, steering system, suspension components (springs, shocks, control arms), wheel alignment
Braking System:
Brake hydraulics, discs, calipers, pads, lines, parking brake, ABS (if applicable)
Electrical System:
Battery, charging system (alternator, starter), ignition system, lighting, instruments, switches, wiring diagrams, ECU troubleshooting
Body And Interior:
Body panels, fenders, doors, hood, tailgate, interior trim, seats, HVAC, safety restraints
Body And Fixtures:
Covers body and fixtures, including doors, latches, hinges, windows, and seals.
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication, adjustments
Repair Procedures:
Component removal, installation, overhaul, and repair for all major vehicle systems
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable)
Special Tools:
Identification and usage of special tools required for specific repairs
Wiring Diagrams Detail:
Includes detailed electrical wiring diagrams for all vehicle systems.
Diagnostic Capabilities:
Advanced diagnostics and troubleshooting for complex systems
Rebuild Procedures:
Detailed procedures for engine, transmission, and differential rebuilds
Specification Detail:
Precise technical specifications, tolerances, torques, and fluid capacities
Engine Options Common:
M104 3.2L Inline-6, M119 4.2L V8, OM603 3.0L Diesel, OM606 3.0L Turbo Diesel (specific engines vary by market and model year)
Horsepower Range:
Approx. 150-230 hp (depending on engine variant)
Torque Range:
Approx. 200-330 lb-ft (depending on engine variant)
Fuel Delivery:
Bosch KE-Jetronic (mechanical fuel injection) or HFM (electronic fuel injection) for gasoline engines; Indirect injection for diesel engines.
Crash Test Results:
While formal modern crash test ratings (NHTSA, Euro NCAP) were less prevalent for this era and vehicle type, the G-Class was built with robust construction principles.
ABS:
Anti-lock Braking System (ABS) was available as an option or standard on later models within this range.
Traction Control:
ASR (Acceleration Slip Regulation) was introduced on some models during this period.
Airbags:
Driver and passenger airbags became available and standard on many models during this generation.
Body Construction:
Ladder-frame chassis construction with a strong steel body offering excellent structural integrity.
Audio System:
Factory-installed AM/FM cassette or CD players, often with premium sound system options.
Navigation:
Optional GPS navigation systems were introduced during this period, often with early CRT or LCD displays.
Cruise Control:
Standard or optional cruise control systems.
Climate Control:
Manual or optional automatic climate control (THERMATIC/THERMOTRONIC).
Phone Integration:
Optional provisions for early cellular phone integration.
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first (consult manual for specific engine).
Major Service Interval:
Varies significantly, with major inspections and component replacements recommended at intervals like 50,000-100,000 km (30,000-60,000 miles).
Engine Oil Spec:
SAE 5W-40, SAE 10W-40, or SAE 15W-40 (API SJ or equivalent for gasoline; specific diesel specs apply for diesel engines). Consult manual for exact API/ACEA ratings.
Coolant Spec:
Ethylene glycol-based coolant, typically a G48 or equivalent (MB 325.0 specification), mixed 50/50 with distilled water.
Brake Fluid Spec:
DOT 4 low-viscosity (LV) brake fluid.
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, exhaust system components, heater blower motor, window regulators, rust (especially on older models).
Engine Specific Concerns:
Head gasket leaks (M104), fuel distributor issues (KE-Jetronic), glow plug issues (diesel).
Transmission Concerns:
Automatic transmission shift quality, potential leaks.
Mercedes Benz Legacy:
Mercedes-Benz has a long-standing reputation for engineering excellence, durability, and luxury, particularly in its off-road and utility vehicles.
W463 Introduction:
The W463 generation marked a significant evolution from the utilitarian W460/W461 series, introducing more creature comforts, improved on-road manners, and a more luxurious interior while retaining its core off-road capability.
Manufacturing Location:
Graz, Austria (by Magna Steyr)
Production Period For Manual:
1990-1997
Off Road Capability Acclaim:
The G-Class has consistently received acclaim for its unparalleled off-road capability and durability, often favored by military, government, and serious off-road enthusiasts.
Durability Reputation:
Renowned for its robust construction and long-term durability, often cited as one of the most over-engineered SUVs.
