Mercedes Benz G wagen 460 230G Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: 460 Specific Model Variant: 230GE (or 230G for carburetor models) Codes Engine Code Common: M102 (for 230GE) 👋 Introduction Market...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

Specific Model Variant:

230GE (or 230G for carburetor models)

Codes

Engine Code Common:

M102 (for 230GE)

👋 Introduction

Market Position

Segment:

Luxury Off-Road Vehicle, Utility Vehicle

Competitive Analysis

Competitors Era:

Land Rover Defender, Toyota Land Cruiser (similar era models)

Key Features

Off Road Capability:

Exceptional off-road prowess due to robust chassis, solid axles, locking differentials, and short overhangs.

Durability:

Renowned for its rugged build quality and longevity, designed for demanding conditions.

Versatility:

Adaptable for military, civilian, and commercial use with various body styles and configurations.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Factory Service and Repair

Page Count

Estimated Pages:

Hundreds (Exact count varies by specific edition, but implies comprehensive coverage)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (Implied by product description and typical market for this manual)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (M102), Fuel System, Exhaust System, Cooling System, Ignition System

Drivetrain:

Manual Transmission, Transfer Case, Drive Axles, Differentials (Front, Rear, Center Lockable), Drive Shafts

Suspension And Steering:

Front and Rear Suspension (Solid Axles, Leaf Springs or Coil Springs depending on variant), Steering Gear, Power Steering System

Brakes:

Front Disc Brakes, Rear Drum Brakes (or Disc depending on specific variant/year), Parking Brake, Brake Lines, Master Cylinder

Electrical System:

Battery, Charging System (Alternator), Starting System, Lighting System, Ignition System, Fuses and Relays, Wiring Diagrams

Body And Chassis:

Frame, Body Panels, Doors, Hood, Tailgate, Seats, Interior Trim, Exterior Trim, Body Sealing

Climate Control:

Heating System, Ventilation, Air Conditioning (if equipped)

Procedures Included

Maintenance:

Routine Inspections, Oil Changes, Filter Replacements, Lubrication Points, Spark Plug Replacement, Belt Adjustments

Troubleshooting:

Diagnostic Procedures, Symptom-Based Troubleshooting Guides, Fault Code Interpretation (if applicable)

Repair:

Component Removal and Installation, Overhaul Procedures, Component Reassembly, Adjustment Procedures

Diagnostics:

Detailed diagnostic steps for all major systems, including electrical component testing and mechanical system checks.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission overhauls. Includes detailed specifications and diagrams.

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

High-resolution, allowing for clear printing of text and diagrams.

Binding Type

Binding Consideration:

N/A (Digital Format - printable for binder use)

Paper Type

Paper Consideration:

N/A (Digital Format - user choice for printing)

Searchability

Text Search:

Searchable text for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, OHC (Overhead Camshaft)

Engine Code:

M102.980 (for 230GE)

Displacement:

2.3 Liters (2299 cc)

Performance

Horsepower Net:

Approx. 125 PS (93 kW; 123 hp) at 5000 rpm (for 230GE with fuel injection)

Torque Net:

Approx. 19.4 kg⋅m (190 N⋅m; 140 lb⋅ft) at 3000 rpm (for 230GE with fuel injection)

Fuel System

Fuel Delivery:

Bosch LE-Jetronic Fuel Injection (for 230GE); Carburetor (for 230G)

Fuel Type

Fuel Required:

Unleaded Gasoline (RON 90 or higher)

Cooling System

Type:

Water Cooled

Ignition System

Type:

Electronic Ignition (Distributorless or Distributor-based, depending on exact M102 variant)

🔧 Transmission

Standard

Transmission Type:

4-speed Manual Transmission (e.g., G3-240/3)

Optional

Transmission Type:

4-speed Automatic Transmission (e.g., 722.3)

Features

Transfer Case:

2-speed transfer case with lockable center differential (standard on most 460 models)

Fluid Specifications

Manual Transmission Fluid:

MB 235.1 specification (e.g., SAE 80W/90 GL-4)

Automatic Transmission Fluid:

MB 236.6 specification (e.g., ATF Dexron II D)

Transfer Case Fluid:

MB 235.1 specification (e.g., SAE 80W/90 GL-4)

Differential Fluid:

MB 235.0 specification (e.g., SAE 90 GL-5 for limited slip, GL-4 otherwise)

📐 Dimensions

Exterior

Wheelbase Short:

2400 mm (94.5 in)

Wheelbase Long:

2850 mm (112.2 in)

Length Short Wb Approx:

4010 mm (157.9 in)

Length Long Wb Approx:

4610 mm (181.5 in)

Width Approx:

1700 mm (66.9 in)

Height Approx:

1950 mm (76.8 in)

Weights

Curb Weight Approx Short Wb:

1900 kg (4189 lbs)

Curb Weight Approx Long Wb:

2000 kg (4409 lbs)

Gross Vehicle Weight Rating Gvwr Approx:

2750 kg (6063 lbs)

Towing Capacity Approx:

2500 kg (5511 lbs)

Approach Angle Approx:

36 degrees

Departure Angle Approx:

36 degrees

Breakover Angle Approx:

29 degrees

Ground Clearance Approx:

235 mm (9.3 in)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Vehicles from this era generally not subjected to modern crash testing standards)

Active Features

Braking System:

Power-assisted front disc brakes, rear drum brakes. Anti-lock Braking System (ABS) may be optional on later models.

Differential Locks:

Driver-controlled locking differentials (center, front, and rear) for extreme off-road traction.

Passive Features

Seat Belts:

3-point front seat belts, 2-point rear seat belts (or 3-point depending on configuration)

Roll Cage:

Integrated roll-over protection structure as part of the body-on-frame construction.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio and cassette player. Some models may have aftermarket upgrades.

Driver Assistance

Traction Control:

Not typically equipped with electronic traction control systems. Relies on mechanical grip and differential locks.

Anti Lock Brakes:

Optional on later models of the 460 series.

Connectivity

Connectivity Features:

None inherent to the era; limited to basic analogue systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 12 months, whichever comes first. Refer to specific manual for exact interval.

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on driving conditions. Refer to manual.

Spark Plug Replacement:

Typically every 30,000 to 60,000 miles (48,000 to 96,000 km). Refer to manual for specific type and gap.

Transmission Fluid Change:

Manual: Every 30,000 to 60,000 miles. Automatic: Every 30,000 to 50,000 miles. Refer to manual.

Fluid Specifications

Engine Oil Capacity:

Approx. 5.0 - 5.5 Liters (4.7 - 5.3 US Quarts) with filter change (M102 engine)

Engine Oil Specification:

API SG/SH or ACEA A2/B2 specification, viscosity typically 10W-40 or 15W-40 depending on climate. Refer to manual for exact MB approval.

Coolant Type:

Ethylene Glycol based antifreeze (e.g., MB 325.0 specification) mixed with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Rust And Corrosion:

Common issue on older vehicles, particularly around wheel arches, rocker panels, and frame areas. Regular inspection and treatment are crucial.

Differential Lock Actuators:

Can seize or fail due to infrequent use or corrosion. Regular engagement and lubrication recommended.

Fuel Pump Reliability:

Early models with mechanical fuel pumps can be prone to failure. Later models with electric pumps are generally more reliable but can still fail.

Heater Core:

Can leak, especially in older vehicles, leading to coolant loss and fogging.

Upholstery And Interior Wear:

Wear and tear on seats, dashboard materials, and carpets is common due to age and use.

Electrical Connectors:

Corrosion or degradation of electrical connectors can lead to intermittent faults.

📚 Vehicle History

Brand Heritage

Brand Origin:

Mercedes-Benz, a pioneer in automotive engineering and luxury vehicles since the late 19th century.

Model Evolution

Development Purpose:

Originally developed in collaboration with the military, emphasizing ruggedness, off-road capability, and durability.

Model Lineage:

The G-Wagen (Geländewagen) has been in continuous production since 1979, with the 460 being the first generation.

Production

Production Period 460:

1979-1991

Manufacturing Location:

Graz, Austria (by Magna Steyr)

🏆 Awards & Recognition

Recognitions

Military Service:

Widely adopted by numerous military forces worldwide, a testament to its robustness and capability.

Ratings

Off Road Capability Rating:

Consistently rated among the top off-road vehicles ever produced for its class.

Certifications

Production Quality:

Built to exacting Mercedes-Benz standards, renowned for precision engineering and build quality.