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...