This comprehensive 1991 Mercedes G-Class (W463) Service and Repair Manual is your one-stop resource for maintaining, servicing, diagnosing, and repairing your vehicle. This manual, which is identical to what technicians use at Mercedes dealerships, covers all models and all repairs from A to Z. With detailed step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications, you'll have everything you need to confidently tackle any repair.

The manual covers a wide range of topics, including:

* **Maintenance:** Learn about routine maintenance tasks like oil changes, filter replacements, and fluid checks.
* **Engine:** Discover information about engine components, troubleshooting, and repair procedures.
* **Control System:** Understand the workings of your car's electronic control systems, including diagnostics and repair.
* **Mechanical:** Explore the mechanical aspects of your vehicle, from the transmission and drivetrain to the suspension and brakes.
* **Fuel Service Specifications:** Find detailed specifications for fuel systems, including injectors, pumps, and lines.
* **Emission Control:** Learn about emission control systems and their components.
* **Intake Exhaust Cooling:** Discover information about intake and exhaust systems, including cooling and related components.
* **Lube:** Find lubrication specifications and recommended fluids for your vehicle.
* **Ignition Starting Charging:** Explore the ignition, starting, and charging systems in detail.
* **Auto Transmission Clutch:** Understand the operation and maintenance of your automatic transmission and clutch.
* **Manual Transmission:** Learn about manual transmissions, including troubleshooting and repair.
* **Transfer Propeller Shaft:** Get detailed information about the transfer case and propeller shaft.
* **Drive Shaft:** Find specific details about drive shafts and related components.
* **Differential:** Learn about the differential, including maintenance and repair.
* **Axle Suspension:** Explore the axle and suspension system, including troubleshooting and repair.
* **Tire & Wheel:** Find information about tires and wheels, including selection, installation, and maintenance.
* **Brake Control:** Understand the brake control system and its components.
* **Brake:** Learn about brake systems, including troubleshooting and repair procedures.
* **Parking Brake:** Get specific details about the parking brake and its operation.
* **Steering Column:** Explore the steering column and its components.
* **Power Steering:** Learn about the power steering system, including troubleshooting and repair.
* **Air Condition:** Find information about the air conditioning system, including maintenance and repair.
* **Suppl Restraint System:** Understand the supplemental restraint system (SRS) and its components.
* **Seat Belt:** Learn about seatbelt systems, including maintenance and repair.
* **Engine Immobilizer:** Explore the engine immobilizer system and its operation.
* **Cruise Control:** Find information about the cruise control system, including troubleshooting and repair.
* **Wiper & Washer:** Learn about the wiper and washer system, including maintenance and repair.
* **Door Lock:** Discover information about door lock systems, including troubleshooting and repair.
* **Meter Audio/Visual:** Explore the meter and audio/visual systems and their components.
* **Horn:** Learn about the horn system, including troubleshooting and repair.
* **Windshield/Glass Mirror:** Find information about the windshield, glass, and mirrors, including replacement instructions.
* **Instrument Panel:** Explore the instrument panel and its components.
* **Seat:** Learn about seats, including adjustment, repair, and replacement.
* **Engine Hood/ Door:** Find information about the engine hood and doors, including troubleshooting and repair.
* **Exterior & Interior:** Explore the exterior and interior of your vehicle, including maintenance and repair.
* **Electrical:** Understand the electrical system of your vehicle, including troubleshooting and repair.
* **Multiplex/ Can Communication:** Learn about multiplexing and CAN communication systems and their operation.

With this comprehensive manual, you'll have the knowledge and tools to keep your 1991 Mercedes G-Class (W463) running smoothly for years to come.

The 1991 Mercedes-Benz G-Class (W463) is a legendary off-road vehicle that embodies ruggedness, durability, and timeless design. This generation saw the introduction of the iconic boxy body style that continues to define the G-Wagon today. Underneath the distinctive exterior, the W463 featured a robust ladder frame chassis, solid axles with independent front suspension, and powerful engine options. Early models were available with a 2.5-liter naturally-aspirated gasoline engine, while later versions received a more powerful 3.0-liter inline-six engine. Despite its off-road capabilities, the G-Class offered a surprisingly comfortable interior with premium materials and a utilitarian layout. The 1991 model year also marked the introduction of the long-wheelbase version, providing additional passenger and cargo space. This versatility made the G-Class a popular choice for both off-road enthusiasts and professionals requiring a vehicle capable of handling challenging terrain.

The G-Class's robust design and impressive performance quickly cemented its status as a highly sought-after vehicle. It became popular with military and law enforcement agencies around the world, notably serving as the preferred vehicle for the Pope. However, the G-Class also gained recognition within the luxury market, attracting celebrities and discerning drivers who appreciated its exclusive status and rugged charm. The 1991 model year marked a significant shift in the G-Class's evolution, paving the way for its continued success and enduring legacy. The W463 generation introduced a host of improvements that enhanced both on-road comfort and off-road capability, making the G-Class a true icon in the automotive world. Its remarkable longevity, timeless design, and unwavering performance have solidified the G-Class as an enduring symbol of luxury, strength, and German engineering excellence.