🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Model Variant: 230G Codes Engine Code: M123 (likely, as a placeholder for the 2.3L petrol engine) 👋 Introduction Market Position Market Segment: Luxury Off-Road Vehicle / Utility Vehicle Target Demographic: Individuals seeking robust, durable, and capable off-road vehicles with a luxury pedigree; also used by military and utility organizations. Competitive Analysis Primary Competitors: Range Rover Classic, Land Rover Defender (early models), Toyota Land Cruiser (early models). Key Features Off Road Capability: Ladder frame chassis, solid axles with long-travel suspension, locking differentials (optional on some models), robust 4WD system providing exceptional articulation and traction. Durability And Longevity: Renowned for its over-engineered construction, designed for extreme conditions and extended service life. Iconic Design: Timeless, utilitarian design characterized by its boxy, angular shape and functional aesthetics. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Cooling System, Exhaust System, Ignition System, Clutch, Transmission (Manual/Automatic), Transfer Case, Drive Axles, Suspension, Steering, Brakes (Front Disc/Rear Drum), Electrical System, Lighting, Bodywork, Interior Trim, Maintenance Procedures, Troubleshooting, Diagnostics, Specifications, Torque Values, Wiring Diagrams. Page Count Estimated Page Count: 500-800 (typical for comprehensive W460 service manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, and reassembly of the 2.3L petrol engine, including cylinder head, block, pistons, crankshaft, camshaft, and valve train. Fuel And Emission Control: Carburetor service (likely Solex or Zenith), fuel pump, fuel lines, fuel filter replacement, emissions control systems (if applicable to the 230G). Cooling System: Radiator, water pump, thermostat, coolant hoses, fan clutch, flush and refill procedures. Ignition System: Distributor, ignition coil, spark plugs, ignition timing adjustment, spark plug wires. Drivetrain Manual Transmission: Clutch replacement, manual transmission overhaul and repair, gear shifting mechanisms. Drivetrain Transfer Case: Transfer case operation, maintenance, and repair, including 4WD engagement and gear reduction. Drivetrain Axles And Differentials: Front and rear axle assembly, differential maintenance and repair, locking differentials (if equipped). Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, articulation of the robust W460 suspension. Steering System: Steering gearbox, steering linkage, power steering pump and system maintenance. Brake System: Front disc brake service (pads, rotors, calipers), rear drum brake service (shoes, drums, wheel cylinders), brake fluid replacement, bleeding procedures. Electrical System: Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams for various circuits. Lighting And Accessories: Headlights, taillights, turn signals, interior lighting, horn, wipers, washers. Body And Chassis: Body panel removal and installation, door mechanisms, hinges, latches, glass replacement, rust prevention and repair guidance. Interior Trim And Upholstery: Dashboard removal, seat adjustments, interior paneling, carpeting. Procedures Included Preventive Maintenance: Oil changes, filter replacements (oil, fuel, air), spark plug replacement, coolant flush, brake fluid flush, lubrication points. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common and uncommon issues, including symptom analysis and component testing. Component Repair And Rebuild: Detailed instructions for the overhaul and repair of all major mechanical and electrical components. Adjustment Procedures: Setting ignition timing, carburetor adjustments, valve clearance adjustments, brake adjustments. Torque Specifications: Comprehensive list of torque values for all critical fasteners throughout the vehicle. Wiring Diagrams: Detailed electrical schematics for all vehicle systems, aiding in troubleshooting and repairs. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including component testing using multimeter and specialized tools (where applicable for the era). Rebuild Scope: Full engine, transmission, and differential rebuild procedures. Special Tools Requirements: Identification of special tools required for specific repair procedures, often referencing Mercedes-Benz specific tooling. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typical for well-scanned PDFs) Printable: Yes Image Quality: High-resolution scans of original manual pages, including diagrams and photographs. Print Quality Print Quality: N/A (Digital PDF format) Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, Petrol Displacement: 2.3 Liters (2299 cc) Bore X Stroke: Approx. 93.0 mm x 83.6 mm (typical for M123 family) Compression Ratio: Approx. 8.3:1 to 8.7:1 (model dependent) Valvetrain: SOHC (Single Overhead Camshaft), 8 Valves Performance Horsepower Net: Approx. 102-125 PS (75-92 kW) at 4800-5200 rpm (varies by market and specific engine tune) Torque Net: Approx. 170-190 Nm (125-140 lb-ft) at 2500-3000 rpm (varies by market and specific engine tune) Fuel System Fuel Delivery: Carburetor (e.g., Solex 32/32 DIDTA or similar twin-choke) Fuel Type: Unleaded Gasoline (Octane rating typically 91 RON or higher) Fuel Tank Capacity: Approx. 75 liters (main tank) + optional auxiliary tank 🔧 Transmission Standard Type: 4-speed Manual Transmission Optional Type: 3-speed Automatic Transmission (e.g., Mercedes-Benz 722.3) Features Transfer Case: 2-speed transfer case with selectable 4WD and low-range gearing. Differential Locks: Center differential lock (standard on W460) and optional front and rear axle locking differentials. 📐 Dimensions Exterior Wheelbase: Approx. 2400 mm (short wheelbase), 2850 mm (long...