🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Chassis Code: W463 Generation Generation Name: First Generation (W463) Codes Product Code Reference: Mercedes Benz 463 G Class Service Repair Manual 1990-1997 👋 Introduction Market Position Vehicle Segment: Luxury SUV / Off-Road Vehicle Target Audience: Owners seeking to maintain and repair their G-Class vehicles, professional mechanics, enthusiasts Competitive Analysis Manual Value Proposition: Provides comprehensive, factory-level repair information, enabling DIY repairs and reducing reliance on expensive dealership services. Offers a complete A-Z coverage. Key Features Manual Layout: Step-by-step instructions with detailed exploded views and diagrams. Accessibility: Instant download for immediate access on PC, tablet, or laptop. 📋 Manual Details Coverage Areas Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Model Variants Covered: All G-Class models (e.g., G300, G320, G350, G350TD, G400, G500, G550 variants as applicable within the specified years) Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive workshop manuals of this era and vehicle complexity) Manual Type Manual Classification: Factory-Style Workshop Manual / Service and Repair Manual Coverage Scope: Comprehensive 'A-Z' coverage for all models and all repairs. Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine removal/installation, fuel system (injection/carburetion), lubrication, cooling, combustion, exhaust, ignition, emission control Transmission Drivetrain: Gearbox (manual/automatic), clutch, transfer case, differentials, drive shafts, axles Chassis Suspension Steering: Frame, front axle, rear axle, steering system, suspension components (springs, shocks, control arms), wheel alignment Braking System: Brake hydraulics, discs, calipers, pads, lines, parking brake, ABS (if applicable) Electrical System: Battery, charging system (alternator, starter), ignition system, lighting, instruments, switches, wiring diagrams, ECU troubleshooting Body And Interior: Body panels, fenders, doors, hood, tailgate, interior trim, seats, HVAC, safety restraints Body And Fixtures: Covers body and fixtures, including doors, latches, hinges, windows, and seals. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication, adjustments Repair Procedures: Component removal, installation, overhaul, and repair for all major vehicle systems Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable) Special Tools: Identification and usage of special tools required for specific repairs Wiring Diagrams Detail: Includes detailed electrical wiring diagrams for all vehicle systems. Technical Depth Diagnostic Capabilities: Advanced diagnostics and troubleshooting for complex systems Rebuild Procedures: Detailed procedures for engine, transmission, and differential rebuilds Specification Detail: Precise technical specifications, tolerances, torques, and fluid capacities 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF format for easy navigation and printing Digital Compatibility: Compatible with Windows, macOS, and Linux operating systems. Print Quality Printability: Printable pages for individual repairs or the entire manual Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options Common: M104 3.2L Inline-6, M119 4.2L V8, OM603 3.0L Diesel, OM606 3.0L Turbo Diesel (specific engines vary by market and model year) Performance Horsepower Range: Approx. 150-230 hp (depending on engine variant) Torque Range: Approx. 200-330 lb-ft (depending on engine variant) Fuel System Fuel Delivery: Bosch KE-Jetronic (mechanical fuel injection) or HFM (electronic fuel injection) for gasoline engines; Indirect injection for diesel engines. 🔧 Transmission Standard Transmission Types: 4-speed Automatic (e.g., 722.4, 722.6) and 5-speed Manual transmissions were available (availability varied by model and year). Optional Transfer Case: Permanent All-Wheel Drive with a 2-speed transfer case and lockable differentials (center and rear as standard/optional). Features Transmission Fluid Spec: ATF Dexron II/III for automatic transmissions; Gear oil SAE 75W-90 or SAE 80W-90 for manual transmissions and differentials. 📐 Dimensions Exterior Wheelbase: 2850 mm (112.2 in) for standard wheelbase models. Overall Length: Approx. 4650 mm (183.1 in) for standard wheelbase models. Weights Curb Weight Range: Approx. 2000-2300 kg (4400-5070 lbs) depending on engine and equipment. Towing Capacity: Typically rated around 3500 kg (7716 lbs). 🛡️ Safety Features Ratings Crash Test Results: While formal modern crash test ratings (NHTSA, Euro NCAP) were less prevalent for this era and vehicle type, the G-Class was built with robust construction principles. Active Features ABS: Anti-lock Braking System (ABS) was available as an option or standard on later models within this range. Traction Control: ASR (Acceleration Slip Regulation) was introduced on some models during this period. Passive Features Airbags: Driver and passenger airbags became available and standard on many models during this generation. Body Construction: Ladder-frame chassis construction with a strong steel body offering excellent structural integrity. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM cassette or CD players, often with premium sound system options. Navigation: Optional GPS navigation systems were introduced during this period, often with early CRT or LCD displays. Driver Assistance Cruise Control: Standard or optional cruise control systems. Climate Control: Manual or optional automatic climate control (THERMATIC/THERMOTRONIC). Connectivity Phone Integration: Optional provisions for early cellular phone integration. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first (consult...