🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Model Code: W463 Year: 1991 👋 Introduction Market Position Target Audience: Mercedes-Benz G-Class (W463) owners, DIY mechanics, independent repair shops Competitive Analysis Value Proposition: Provides factory-level, vehicle-specific repair and maintenance data, surpassing generic repair guides. Key Features Instruction Style: Complete step-by-step instructions with diagrams, illustrations, and schematics. Usability: Single, easy-to-use PDF manual, printable pages for workshop use, no more physical manual wear and tear. Diagnostic Capability: Enables in-depth diagnosis and repair, reducing reliance on dealerships for routine issues. Illustrations: High-quality, detailed illustrations and diagrams that clearly show component location, orientation, and assembly order. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Maintenance, Repair, Diagnostics Scope: All Models & All Repairs A-Z Page Count Estimated Pages: Extensive (Implied by comprehensive coverage) Manual Type Type: Service and Repair Manual Source: Factory Service Information Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel Service, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition, Starting/Charging, Auto Transmission, Manual Transmission, Transfer Case, Differential, Axle Chassis: Suspension, Tire & Wheel, Brake Control, Brakes, Parking Brake, Steering Column, Power Steering Body & Electrical: Air Conditioning, Supplemental Restraint System (SRS), Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Locks, Meter/Audio/Visual, Horn, Windshield/Glass/Mirror, Instrument Panel, Seats, Engine Hood/Doors, Exterior & Interior, Electrical Systems, Multiplex/CAN Communication Body And Frame: Frame structure, body panel repair, door mechanisms, hinges, locks, glass replacement, and interior trim. Lighting And Signals: Headlights, taillights, turn signals, interior lighting, and associated wiring. Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections Repair: Component Removal & Installation, Overhauls, Adjustments, Diagnoses Diagnostics: Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs) Torque Specifications: Crucial torque values for all critical fasteners across engine, transmission, chassis, and suspension components. Troubleshooting Charts: Systematic guides for diagnosing faults based on symptoms, with cross-references to relevant sections. Technical Depth Depth: Factory-Level Detail, Step-by-Step Instructions, Comprehensive Diagrams and Illustrations Diagnostics Detail: Advanced Diagnostic Procedures, Wiring Schematics for Electrical Systems Engine Rebuild: Instructions for complete engine disassembly, inspection, and reassembly. Transmission Overhaul: Detailed procedures for automatic and manual transmission rebuilds, including component identification and assembly sequence. 📊 Manual Specifications File Format File Type: PDF Searchability: PDF format allows for text searching of keywords and components. Print Quality Printability: All pages printable, scalable images Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format, printable on user's choice of paper) Software Requirements Reader: Adobe PDF Reader Unzipping: Winzip (or equivalent) Compatibility Operating Systems: Windows (Vista32/64, XP, ME, 98, NT, 2000) and Mac ⚙️ Engine Specifications Primary Engine Engine Type: This manual covers various W463 engine configurations for 1991. Common engines include gasoline (e.g., M102 2.3L, M103 3.0L) and diesel (e.g., OM602 2.9L). Performance Horsepower Torque: Specific figures vary by engine. The manual will detail Horsepower and Torque curves for each applicable engine. Fuel System Fuel Delivery: Fuel Injection (likely Bosch KE-Jetronic or similar for gasoline, indirect injection for diesel). Manual details fuel pump, injectors, pressure regulator, and diagnostic procedures. Fuel Filter Replacement: Detailed instructions for locating and replacing the fuel filter, including necessary precautions. Cooling System Cooling Type: Pressurized liquid cooling system. Manual covers radiator, fan, water pump, thermostat, hoses, and coolant specifications. Lubrication Oil System: Forced lubrication. Manual details oil pump, oil filter, oil cooler (if equipped), and oil specifications (e.g., MB 229.1 or similar for the era). 🔧 Transmission Standard Type 1991: Likely a 4-speed automatic or 5-speed manual transmission, depending on the specific G-Class variant. The manual covers both. Gear Ratios: The manual will provide detailed gear ratios for both manual and automatic transmissions fitted to the 1991 W463. Optional Transmission Options: Details on available automatic and manual transmission variants for the 1991 model year. Features Transmission Fluid: Specifications and capacities for automatic transmission fluid (e.g., Dexron II or equivalent Mercedes-spec ATF) and manual transmission oil. Transfer Case Transfer Case Operation: Information on the G-Class's robust 4x4 system, including locking differentials (if applicable to the 1991 model), transfer case maintenance, and repair. 📐 Dimensions Exterior Wheelbase: Varies by specific G-Wagen body style (e.g., short wheelbase, long wheelbase). Manual will list for each variant. Ground Clearance: Significant ground clearance inherent to the G-Class design. Specific figures provided in manual. Tire Size: Common sizes for this era might include 205R16, 225/75R16, or similar. Manual will specify correct sizes for different trims/models. Wheel Bolt Pattern: Typically 5x112mm for Mercedes-Benz vehicles of this era. Manual will confirm. Weights Curb Weight: Varies significantly by engine and body style, typically in the range of 4,400 - 5,000 lbs (approx. 2000-2300 kg). Gross Vehicle Weight Rating: Detailed GVWR for each model variant will be present in the manual. 🛡️ Safety Features Ratings Crash Test Results: Information on early safety standards and G-Class's robust chassis design; specific ratings from this era might be limited but structural...