Positioning:
The Mercedes-Benz G-Wagen (W460) occupied a unique niche as a highly capable off-road vehicle with luxury and refinement, bridging the gap between utilitarian off-roaders and premium SUVs.
Competitors:
Competed indirectly with vehicles like the Range Rover Classic, Toyota Land Cruiser (FJ60/62), and Jeep Grand Wagoneer, though its military origins and distinct Mercedes-Benz engineering set it apart.
G Wagen Attributes:
Robust ladder frame chassis, selectable four-wheel drive with locking differentials (often standard or optional across the range), strong body-on-frame construction, and a focus on durability and off-road prowess.
Years Covered:
1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Type:
Workshop Service Manual
Language:
English (Assumed, standard for workshop manuals of this era and origin)
Engine:
Complete engine overhaul, tuning, diagnosis, fuel system, lubrication, cooling, ignition (for gasoline M123 engine).
Transmission:
Manual and automatic transmission service, repair, and overhaul.
Drivetrain:
Transfer case, differentials, driveshafts, axles, CV joints, and hub mechanisms.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, and steering linkage.
Brakes:
Front disc and rear drum brake systems, hydraulic lines, master cylinder, calipers, wheel cylinders, parking brake.
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting system, ignition system, instrumentation, fuses, relays, and common electrical faults.
Fuel System:
Carburetor (Zenith Stromberg or similar for 230G), fuel pump, fuel lines, fuel tank, and emissions control systems.
Body And Chassis:
Body panel removal and installation, chassis frame inspection and repair, doors, windows, seats, and interior trim.
Cooling System:
Radiator, fan, water pump, thermostat, hoses, and coolant.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), mufflers, and exhaust pipes.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, lubrication points, and inspections.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components.
Troubleshooting:
Diagnostic charts, symptom analysis, and common problem resolution for various systems.
Overhaul:
Complete engine, transmission, and differential overhaul procedures with specifications.
Adjustment:
Carburetor tuning, ignition timing, valve clearance adjustment, and clutch adjustment.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Depth:
Comprehensive, covering from basic maintenance to in-depth mechanical and electrical repairs, suitable for professional technicians and advanced DIYers.
Engine Type:
Inline-4 Cylinder, Overhead Valve (OHV) or Overhead Cam (OHC) depending on specific M123 variant.
Displacement Cc:
2299 cc (for 230G)
Bore X Stroke Mm:
87.0 mm x 95.0 mm (approximate for M123 family)
Compression Ratio:
8.0:1 or 8.5:1 (typical for M123)
Horsepower Ps:
102-125 PS (approximate, varies by specific model year and configuration of the M123)
Torque Nm:
165-180 Nm (approximate, varies by specific model year and configuration of the M123)
Fuel Delivery:
Carburetor (e.g., Zenith Stromberg, Solex, or similar)
Fuel Type:
Unleaded Gasoline (Petrol)
Ignition Type:
Distributor-based, points or electronic (depending on year).
Transmission Type:
4-speed manual transmission (common for 230G in early years)
Transmission Type:
3-speed or 4-speed automatic transmission (optional, increasingly common through the production run).
Transfer Case:
2-speed transfer case with selectable 4WD and optional differential locks (center, front, rear).
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact MB specification).
Automatic Transmission Fluid:
Mercedes-Benz Automatic Transmission Fluid (ATF) specification, likely DEXRON II or equivalent (refer to manual for exact MB specification).
Wheelbase Mm:
2400 mm (standard wheelbase for W460)
Length Mm:
3745 mm (approximate for short wheelbase variants)
Width Mm:
1760 mm (approximate)
Height Mm:
1940 mm (approximate, varies with body style)
Ground Clearance Mm:
Approx. 200 mm (varies with tire size and suspension)
Curb Weight Kg:
1800 - 2000 kg (approximate, depends on body style and equipment)
Gross Vehicle Weight Kg:
Approx. 2700 kg (varies)
Towing Capacity Kg:
Up to 2000 kg (varies by configuration and region)
Crash Test Data:
No formal NTHSA/Euro NCAP ratings for this era, designed to military/civilian robustness standards.
Braking System:
Power-assisted front disc brakes, rear drum brakes. ABS was not standard in this era.
Seat Belts:
Standard three-point front seatbelts, lap belts for rear passengers.
Body Construction:
Rugged body-on-frame construction designed for durability and impact resistance.
Roll Over Protection:
Integral roll cage structure within the body, providing significant rollover protection.
Oil Change Interval Km:
Every 7,500 - 10,000 km or 12 months (typical for the era, refer to manual for specifics).
Major Service Interval Km:
Every 30,000 - 50,000 km for comprehensive checks and fluid changes (refer to manual).
Engine Oil Spec:
API SF/SG, SAE 10W-40 or 15W-40 (check manual for exact MB specification and viscosity for climate).
Coolant Spec:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mercedes-Benz spec coolant recommended.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid (check manual for exact specification).
Power Steering Fluid:
Mercedes-Benz Power Steering Fluid or equivalent ATF specification (check manual).
Common Wear Items:
Bushings (suspension, body), exhaust system components, brake wear, fuel system components (carburetor seals), aging rubber seals and hoses.
Rust Prone Areas:
Wheel wells, rocker panels, chassis frame, tailgate, and areas where water can collect. Early models require vigilance against corrosion.
Engine Specific Notes:
M123 gasoline engines are generally robust but can suffer from carburetor issues and potential oil leaks if not maintained. Valve adjustments are crucial.
Mercedes Benz Legacy:
Mercedes-Benz has a long history of engineering robust and reliable vehicles, including military vehicles, which informed the G-Wagen's development.
W460 Introduction:
The W460 G-Wagen was developed in collaboration with Steyr-Daimler-Puch in Austria and introduced in 1979, initially for military and civilian utility purposes.
W460 Facelifts:
The W460 received minor updates throughout its lifespan, but its core design remained consistent until the introduction of the W463 generation in 1990.
Manufacturing Location:
Graz, Austria, by Magna Steyr (formerly Steyr-Daimler-Puch AG) under contract for Mercedes-Benz.
Production Period W460:
1979-1993 (W460 production continued alongside the W463 for a period).
