🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Chassis Code: W463 Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 👋 Introduction Market Position Vehicle Segment: Luxury Off-Road SUV / All-Wheel Drive (AWD) Target Audience: Enthusiasts, owners performing DIY maintenance and repairs, independent workshops specializing in Mercedes-Benz. Competitive Analysis Competitors Early 90S: Land Rover Range Rover, Toyota Land Cruiser, Jeep Grand Cherokee (though G-Class occupied a unique, more utilitarian yet luxurious niche). Key Features Vehicle Identity: The W463 G-Class is renowned for its exceptional off-road capability, robust construction, distinctive boxy styling, and luxurious interior appointments, differentiating it from most contemporary SUVs. Manual Value Proposition: Empowers owners to maintain and repair their vehicle, saving significant costs associated with dealership services. Provides detailed, accurate information for complex tasks. 📋 Manual Details Coverage Areas General Coverage: Complete workshop service and repair procedures for Mercedes-Benz W463 G-Class models from 1990-1997. Engine Coverage: All gasoline and diesel engine variants offered for the W463 chassis during the specified years. Transmission Coverage: All automatic and manual transmission types, including transfer case. Trim And Options Coverage: All trim levels, body styles, and optional equipment. Page Count Estimated Pages: Extensive (typical for comprehensive workshop manuals covering multiple years and configurations). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Format: Digital Downloadable (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, lubrication, cooling, fuel injection (including mechanical and electronic systems), ignition, exhaust, diesel injection, turbocharging. Transmission Drivetrain: Automatic transmission (e.g., 722.4, 722.6 variants), manual transmission, transfer case, driveshafts, differentials, axles. Chassis Suspension Steering: Front and rear suspension (coil springs, shocks, control arms), steering system (power steering), wheel alignment. Brakes: Hydraulic brake systems (ABS if equipped), disc and drum brake components, parking brake. Electrical Electronic: Battery, charging system, starting system, lighting system, instrumentation, wipers, horn, power accessories, basic diagnostic codes. Body And Interior: Body panels, doors, windows, seats, interior trim, HVAC system, fuel tank, exhaust system routing. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, belt inspections and tensioning, spark plug replacement, air filter replacement. Engine Repair: Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing component replacement. Transmission Repair: Transmission removal/installation, internal component repair (where feasible in a manual), fluid and filter changes. Brake Service: Brake pad and rotor replacement, caliper service, brake fluid flush and bleeding, parking brake adjustment. Electrical Diagnostics: Troubleshooting electrical circuits, component testing, wiring diagram interpretation. Suspension Steering Repair: Replacement of ball joints, tie rod ends, shock absorbers, springs, power steering pump and rack service. Troubleshooting: Diagnostic charts and procedures for common symptoms and issues. Body Repair: Body panel alignment, door and window mechanisms, tailgate repair, bumper repair/replacement. HVAC System: Heater core replacement, blower motor service, AC system diagnostics and recharging (where applicable). Wiring Diagrams: Detailed wiring diagrams for various electrical systems, crucial for troubleshooting. Technical Depth Depth: Comprehensive; covers everything from basic maintenance and fluid changes to complete engine and transmission rebuilds, and detailed diagnostic procedures. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High Quality (as stated in product description), suitable for printing. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Software Requirements Required Software: Adobe Reader (or compatible PDF viewer) ⚙️ Engine Specifications Primary Engine M103 Engine Code: M103 Engine Type: 3.0L Inline-6 SOHC Bore X Stroke: 88.5 mm x 80.2 mm Compression Ratio: 9.2:1 Horsepower: Approx. 170-180 hp @ 5700 rpm Torque: Approx. 180-188 lb-ft @ 4400 rpm Primary Engine M104 Engine Code: M104 Engine Type: 3.2L Inline-6 DOHC (24-valve) Bore X Stroke: 89.9 mm x 84.0 mm Compression Ratio: 9.0:1 or 10.0:1 (depending on variant) Horsepower: Approx. 210-230 hp @ 5500-6000 rpm Torque: Approx. 221-236 lb-ft @ 3750-4500 rpm Diesel Engines Diesel Variants: OM602 (2.9L I5 Diesel), OM603 (3.0L I6 Diesel), OM606 (3.0L I6 Turbo Diesel). Fuel System Fuel Delivery Gasoline: Bosch KE-Jetronic (CIS-E) or HFM (Hot Film Mass Airflow) fuel injection system. Fuel Delivery Diesel: Mechanical or electronic diesel injection pump. 🔧 Transmission Standard Transmission Standard Type: Often equipped with a 4-speed automatic transmission (e.g., 722.4). Optional Transmission Optional Type: Later models and specific variants might have a 5-speed automatic (e.g., 722.6) or a 5-speed manual transmission. Features Transfer Case: Permanent all-wheel drive with a 2-speed transfer case and lockable center differential, rear differential, and front differential (often selectable). 📐 Dimensions Exterior Long Wheelbase Length: Approx. 4665 mm (183.7 in) for long wheelbase versions. Exterior Short Wheelbase Length: Approx. 4060 mm (159.8 in) for short wheelbase versions (less common in W463 for this era). Exterior Width: Approx. 1760 mm (69.3 in). Height: Approx. 1931 mm (76.0 in). Weights Curb Weight: Approx. 4800-5500 lbs (2177-2495 kg), varies significantly by engine and equipment. 🛡️ Safety Features Ratings Crash Test Standards: While specific contemporary NHTSA/Euro NCAP ratings for this exact...