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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 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: PDF 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...
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Mercedes Benz G wagen 460 230G Factory Service Repair Manual
🏷️ 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 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:
PDF
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.
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