🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Model Code: W463 Year: 1990-1994 Codes Chassis Code: W463 Internal Model Designation: G-Wagen 👋 Introduction Market Position Segment: Luxury SUV, Off-Road Vehicle Target Audience: Owners, independent repair shops, enthusiasts focusing on robust off-road capability and luxury. Competitive Analysis Key Competitors: Land Rover Defender (though less luxury), Toyota Land Cruiser (different focus), Jeep Grand Cherokee (different segment). Key Features Defining Characteristics: Legendary off-road prowess, robust body-on-frame construction (though W463 moved to more integrated body), exceptional durability, luxury appointments. Manual Value Proposition: Enables owners and technicians to maintain and repair a highly capable, complex vehicle, preserving its longevity and performance. 📋 Manual Details Coverage Areas Scope: Comprehensive workshop and service repair Page Count Total Pages: 341 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagnosis, repair, and overhaul procedures for all applicable engine variants. Engine Management: Fuel injection systems, ignition timing, emission controls, ECU diagnosis and programming. Transmission Manual: Repair and overhaul of manual gearboxes, clutch system diagnosis and replacement. Transmission Automatic: Diagnosis, repair, and fluid service for automatic transmissions. Drivetrain 4X4: Center differential, locking differentials, transfer case operation and repair, driveshafts, U-joints. Suspension And Steering: Front and rear suspension components, springs, shock absorbers, steering gear, power steering system. Brakes: Front and rear brake systems (disc/drum), ABS operation and diagnostics, brake fluid service. Electrical System: Starting and charging system, battery, lighting systems, wiring diagrams, fuses, relays. Body And Chassis: Body panel repair, doors, hood, tailgate, interior trim, chassis lubrication. Heating Ventilation Air Conditioning: HVAC system diagnosis, repair, refrigerant service, climate control. Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter replacement. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipework. Cooling System: Radiator, water pump, thermostat, coolant specifications, flushing and refilling. Wheels And Tires: Tire pressure, rotation, replacement, wheel balancing, wheel specifications. Procedures Included Scheduled Maintenance: Detailed maintenance schedules and procedures for all intervals. Troubleshooting: Systematic diagnostic procedures and fault code interpretation. Repair And Overhaul: Step-by-step instructions for component removal, repair, and reinstallation. Diagnostics: On-board diagnostics (OBD) information and diagnostic tool usage. Specifications Data: Torque specifications, clearances, fluid capacities, electrical values. Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems. Technical Depth Depth: Expert-level, covering from routine maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format PDF Version: Likely PDF 1.4 or higher, optimized for readability and searchability. Print Quality Resolution: High resolution, ensuring clarity of diagrams, schematics, and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: Likely includes M102 (2.3L Inline-4), M103 (3.0L Inline-6), M104 (3.2L Inline-6), M117 (5.0L V8), OM602 (2.9L Diesel Inline-5), OM603 (3.0L Diesel Inline-6). Performance Horsepower Range: Approximately 115 HP (Diesel) to 220 HP (V8). Torque Range: Approximately 220 Nm (Diesel) to 380 Nm (V8). Fuel System Fuel Delivery: Bosch K-Jetronic (early models) or Lambda Control (KE-Jetronic) fuel injection for gasoline engines; indirect injection for diesel engines. Engine Type Configuration: Inline-4, Inline-6, V8 (gasoline); Inline-5, Inline-6 (diesel). Engine Codes Common Gasoline: M102, M103, M104, M117 Common Diesel: OM602, OM603 🔧 Transmission Standard Transmission Type Gasoline: Likely 5-speed manual or 4-speed automatic (722.4, 722.5). Transmission Type Diesel: Likely 4-speed or 5-speed manual, or 4-speed automatic. Optional Optional Transmission: Higher-performance automatic transmissions may have been available on certain models. Features Transfer Case: Permanent four-wheel drive with lockable center and rear differentials (optional on some models, standard on many). Fluid Specifications Automatic Transmission Fluid: Refer to manual for specific ATF type (e.g., Dexron III or equivalent for 722.4/722.5). Manual Transmission Fluid: Refer to manual for specific gear oil type (e.g., MB 235.0 or 235.1). 📐 Dimensions Exterior Body Styles: 3-door, 5-door (SUV), cabriolet, panel van, pickup (less common). Wheelbase: Approx. 2850 mm (5-door), 2400 mm (3-door). Weights Curb Weight: Approx. 2000 kg to 2300 kg depending on configuration. 🛡️ Safety Features Ratings Crash Test Data: Specific crash test data for this era may be limited, but known for robust construction. Active Features ABS: Anti-lock Braking System (ABS) was optional on earlier models and standard on later W463 variants. Passive Features Airbags: Driver airbag standard on later models; passenger airbag optional. Chassis Construction: Strong ladder frame chassis with integrated body structure for enhanced rigidity and safety. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player, optional CD player on later models. Navigation: No integrated navigation systems in these early models. Driver Assistance Cruise Control: Optional cruise control system. Connectivity External Ports: No modern connectivity features like USB or Bluetooth. 🔧 Maintenance Service Intervals Oil Change Interval Gasoline: Typically 10,000 km or 12 months, whichever comes first. Oil Change Interval Diesel: Typically 7,500 km or 12 months, whichever comes first. Major Service Intervals: Refer to manual for 40,000 km, 80,000 km,...