Mercedes Benz G wagen 460 230G Service Repair Factory Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Specific Model Variant: 230GE Generation Generation Code: First Generation (W460) Codes Engine Code Associated: M102 👋 Introduction Market Position...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

Specific Model Variant:

230GE

Generation

Generation Code:

First Generation (W460)

Codes

Engine Code Associated:

👋 Introduction

Market Position

Vehicle Classification:

Luxury SUV, Off-Road Vehicle

Target Audience:

Enthusiasts, off-roaders, and owners seeking in-depth maintenance and repair knowledge

Competitive Analysis

Competitors:

Range Rover Classic, Land Rover Defender (early models), Toyota Land Cruiser (J40/J60 series)

Key Features

Vehicle Design Philosophy:

Rugged, utilitarian, go-anywhere capability with Mercedes-Benz build quality and luxury appointments

Manual Value Proposition:

Provides essential, detailed technical information for maintaining and repairing a classic and capable off-road vehicle, crucial for preserving its functionality and value.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, repair, and workshop procedures

Page Count

Estimated Page Count:

Varies by edition, typically 800-1200 pages

Manual Type

Type:

Factory Service/Workshop Manual

Language

Language:

English

Format

Format:

Digital (likely PDF), potentially printed versions available

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical (disassembly, assembly, overhaul), lubrication, cooling, fuel, ignition, emissions control systems

Transmission:

Manual and automatic transmissions (service, repair, overhaul), transfer case, driveshafts

Drivetrain:

Front and rear axles, differentials, locking differentials (if equipped), hubs, wheel bearings

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, bushings, alignment procedures

Brakes:

Disc brake systems (front and rear), hydraulic system, parking brake, ABS (if equipped)

Steering:

Power steering system, steering gearbox, steering linkages, column

Electrical:

12V electrical system, battery, alternator, starter, lighting systems, ignition system, engine control unit (ECU), sensors, wiring diagrams, fuse/relay identification

Body:

Body panels, doors, windows, locks, latches, hinges, interior trim, exterior trim, glass replacement, chassis repairs

HVAC:

Heating, ventilation, and air conditioning (HVAC) system service and repair

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injection system (K-Jetronic or similar)

Procedures Included

Maintenance:

Routine maintenance (oil changes, filter replacements, spark plugs), fluid checks and changes, lubrication points

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs) for applicable systems, symptom-based troubleshooting

Repair:

Component removal, installation, overhaul, adjustment, and replacement for all major systems

Overhaul:

Detailed procedures for complete engine, transmission, and differential rebuilds

Installation:

Installation procedures for specific components and accessories

Specifications:

Torque specifications, tolerances, clearances, fluid capacities, electrical specifications

Technical Depth

Depth:

Factory-level, including detailed exploded views, schematics, and step-by-step instructions suitable for professional mechanics and experienced DIY enthusiasts

📊 Manual Specifications

File Format

Digital Format:

PDF (searchable text and high-resolution images expected)

Print Quality

Image Resolution:

High-resolution, clear diagrams and illustrations

Binding Type

Physical Binding:

N/A (for digital), Spiral or perfect bound (for print versions)

Paper Type

Physical Paper:

Durable, matte finish paper suitable for workshop environments (for print versions)

⚙️ Engine Specifications

Primary Engine

Engine Family:

M102 Inline-4

Engine Type:

Spark-ignition, naturally aspirated, gasoline

Displacement:

2.3 Liters (2299 cc)

Bore X Stroke:

93.7 mm x 83.6 mm

Compression Ratio:

8.3:1 or 9.0:1 (depending on specific variant)

Valvetrain:

Single Overhead Camshaft (SOHC), 2 valves per cylinder

Performance

Horsepower:

Approximately 125 PS (92 kW; 123 hp) at 5000 rpm

Torque:

Approximately 192 Nm (142 lb-ft) at 3200 rpm

Fuel System

Fuel Delivery:

Bosch K-Jetronic mechanical fuel injection

Fuel Type:

Unleaded gasoline (premium recommended)

Cooling System

Coolant Type:

Mercedes-Benz approved coolant concentrate (e.g., MB 325.0 or 326.0)

Lubrication

Engine Oil Specification:

API SG/SH or ACEA A2-96 or better, viscosity SAE 15W-40 or 10W-40 (refer to manual for climate-specific recommendations)

Oil Capacity:

Approximately 6.0 Liters (with filter)

🔧 Transmission

Standard

Transmission Type:

4-speed manual transmission (e.g., GW 460)

Optional

Transmission Type:

4-speed automatic transmission (e.g., 722.3 series)

Features

Transfer Case:

2-speed transfer case with selectable 4WD and locking center differential

Transmission Fluid Manual:

API GL-4 (e.g., MB 235.0, SAE 80W-90)

Transmission Fluid Automatic:

MB 236.6 specification (e.g., Dexron IIE compatible), SAE 10W

📐 Dimensions

Exterior

Wheelbase Short Wheelbase:

2400 mm (approx. 94.5 inches)

Wheelbase Long Wheelbase:

2850 mm (approx. 112.2 inches)

Ground Clearance:

Approx. 205 mm (8.1 inches) to 215 mm (8.5 inches) depending on tire size and suspension

Weights

Curb Weight Short:

Approx. 1800 - 1900 kg

Curb Weight Long:

Approx. 1900 - 2000 kg

Gross Vehicle Weight Rating:

Approx. 2700 - 2900 kg

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not directly comparable to modern standards due to era of production; designed for robustness rather than passive crash deformation energy management in the modern sense.

Active Features

Braking System:

Front ventilated disc brakes, rear drum brakes (later models may feature rear discs), power assisted

Traction Control:

Available locking differentials (center, rear, and sometimes front) manually engaged for extreme off-road traction

Passive Features

Seat Belts:

Lap and shoulder belts standard

Body Construction:

Robust body-on-frame construction for durability and off-road capability

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, cassette player (optional upgrades available)

Climate Control:

Manual ventilation, heater, optional air conditioning

Driver Assistance

Optional on later W460 models, more common on W463

Locking Differentials:

Key technology for off-road capability, manually selectable

Connectivity

Connectivity Features:

None by modern standards; designed for robust mechanical operation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 - 10,000 km (or annually), consult manual for specific year/engine

Air Filter Replacement:

Every 15,000 - 20,000 km or as needed based on driving conditions

Spark Plug Replacement:

Every 20,000 - 30,000 km

Transmission Fluid Change:

Manual: Every 60,000 km; Automatic: Every 40,000 - 50,000 km (highly recommended)

Coolant Flush:

Every 2 years or 40,000 km

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

MB specification (e.g., MB 236.3) or equivalent ATF

Differential Oil Type:

API GL-5 (e.g., MB 235.0), SAE 80W-90

Known Issues

Common Wear Items:

Ball joints, tie rod ends, universals joints, fuel pump (K-Jetronic), vacuum lines, exhaust system components, body rust (especially around wheel wells, chassis points)

Engine Specific:

M102 engine can be sensitive to cooling system maintenance; potential for head gasket issues if overheated.

Electrical Gremlins:

Can occur with age; check grounds, connectors, and wiring harness integrity.

📚 Vehicle History

Brand Heritage

Manufacturer Legacy:

Mercedes-Benz, renowned for engineering excellence, luxury, and durability since the early 20th century.

Model Evolution

Development Origin:

Conceived in the 1970s for military and off-road use, evolving into a civilian luxury and highly capable off-road vehicle.

W460 Introduction Year:

W460 Production End Year:

Production

Manufacturing Locations:

Graz, Austria (by Magna Steyr)

Initial Purpose:

Developed in cooperation with the German military

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

Widely recognized for its exceptional off-road prowess and durability, earning a legendary status among adventurers and off-road enthusiasts.

Longevity Status:

Considered an icon of automotive durability and capability, with many W460 models still in active use and highly valued.