🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Class

Chassis Code:

W463

Model Year:

1982

Production Code Reference:

W463 series designation for the G-Class

👋 Introduction

Positioning:

The 1982 Mercedes-Benz G-Class (W463) was positioned as a robust, go-anywhere off-road vehicle with luxury and refinement, a departure from typical utilitarian SUVs.

Competitors:

Competed with other high-end off-road vehicles like the Range Rover, but often distinguished by its superior build quality, more utilitarian chassis roots, and distinct Mercedes-Benz engineering.

Features:

Renowned for its exceptional off-road capability with standard locking differentials, ladder frame construction, solid axles, and robust powertrains. Known for durability and longevity.

Legacy Status:

The G-Class, even in its early iterations, established a reputation for unparalleled off-road capability and ruggedness, a legacy that continues to this day.

Audience:

Ideal for Mercedes-Benz G-Class owners, independent repair shops, and automotive enthusiasts looking for authentic, factory-level repair information.

📋 Manual Details

Coverage:

All models and all repairs A-Z for the 1982 Mercedes-Benz G-Class (W463)

Page Count:

Not specified, but described as 'complete' and 'everything you will ever need'

Type:

Service and Repair Manual

Language:

English

Format:

PDF (printable)

Description:

This is a comprehensive, vehicle-specific service and repair manual for the 1982 Mercedes-Benz G-Class. It is the same manual used by dealership technicians and provides detailed, step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for all maintenance, service, diagnosis, and repair procedures.

Digital Benefits:

Offers flexibility for technicians and DIY mechanics to print only necessary pages, store digitally to prevent damage, and zoom in on intricate diagrams for clarity.

📖 Manual Coverage

Systems:

Maintenance, Engine, Control System, Mechanical, Fuel Service Specifications, Emission Control, Intake Exhaust Cooling, Lube, Ignition Starting Charging, Auto Transmission Clutch, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle Suspension, Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering, Air Condition, Suppl Restraint System, Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/ Door, Exterior & Interior, Electrical, Multiplex/ Can Communication, and much more.

Procedures:

Step-by-step instructions for maintenance, service, diagnosis, and repair. Includes troubleshooting, component replacement, and adjustment procedures.

Depth:

Factory high-detail, vehicle-specific information identical to dealership technician manuals. Covers routine maintenance to complete overhauls and diagnostics.

Electrical Coverage:

Detailed coverage of all electrical systems, including lighting, starting and charging systems, ignition, instruments, wipers, horns, power accessories, and wiring schematics for diagnosis and repair.

Diagnostic Coverage:

Includes systematic diagnostic procedures for all major systems, helping technicians identify the root cause of faults using symptom-based troubleshooting trees and component testing methods.

Body Chassis Coverage:

Comprehensive coverage of the vehicle's body-on-frame construction, including frame inspection, rust repair, panel replacement, door mechanisms, hinges, latches, and exterior trim.

Brake System Coverage:

Detailed procedures for front and rear disc/drum brakes, hydraulic system components (master cylinder, calipers, wheel cylinders, brake lines), parking brake system, and brake bleeding.

Interior Coverage:

Detailed procedures for interior trim, seats, dashboard, instrument panel, door panels, headliner, and related components.

📊 Manual Specifications

Format:

PDF

Searchability:

PDF format allows for easy searching of keywords, facilitating quick access to specific repair information.

Printability:

All pages are printable. Ability to blow up images and print enlarged copies.

Binding:

Digital (PDF) - no physical binding

Paper Type:

Not applicable (digital format)

Software:

Adobe PDF Reader, Winzip (free online). Compatible with Windows Vista (32/64), XP, ME, 98, NT, 2000, and Mac.

⚙️ Engine Specifications

Engine Options 1982:

Likely featured the M102 2.3L inline-4 gasoline engine and OM602 3.0L inline-5 diesel engine. Specific engine variants would depend on the market and trim level (e.g., 230 GE, 300 GD).

Horsepower Torque Range:

Approximately 90-125 hp for diesel variants and 100-130 hp for gasoline variants. Torque figures would vary accordingly, emphasizing low-end grunt for off-road use.

Fuel System Type:

Carbureted for gasoline engines (e.g., Solex or Weber) and Bosch mechanical injection for diesel engines.

Fuel Tank Capacity:

Fuel tank capacity varied by model, but typically in the range of 70-100 liters. Specific capacity will be detailed.

Engine Codes Common:

Common engine codes for this era would include M102 (gasoline inline-4) and OM602 (diesel inline-5), though specific engine variants for 1982 might differ slightly from later W463 models.

Cooling System Description:

Robust cooling system design with radiator, fan (mechanical), thermostat, water pump, and coolant reservoir. Manual covers diagnosis and repair of overheating issues, leaks, and component failures.

Ignition System Description:

Conventional breaker-point ignition system or early electronic ignition systems. Manual covers spark plugs, ignition coils, distributors, and timing adjustments.

Emission Control Systems:

Details on emission control components relevant to 1982 regulations, such as catalytic converters (if equipped), exhaust gas recirculation (EGR), and vacuum routing for emission systems.

🔧 Transmission

Transmission Type Standard:

4-speed or 5-speed manual transmission (e.g., G4/27) was common.

Transmission Type Optional:

A 3-speed or 4-speed automatic transmission may have been available as an option on some models.

Transmission Features:

Integrated with a robust transfer case providing selectable 2WD/4WD and often featuring locking center differential (and sometimes front/rear axle differentials).

Gear Ratios Manual:

Specific gear ratios for manual transmissions (e.g., G4/27 or similar) would be detailed in the manual, crucial for understanding performance and torque application.

Transfer Case Description:

Key feature is the robust transfer case with selectable 4WD and differential locks. Manual will detail operation, maintenance, and repair of the transfer case and its associated mechanisms.

Clutch System Coverage:

For manual transmissions, the manual details clutch disc, pressure plate, release bearing replacement, hydraulic clutch system service, and adjustment procedures.

Drive Shaft Coverage:

Includes inspection, maintenance, and replacement of front and rear drive shafts, universal joints, and center support bearings.

📐 Dimensions

Wheelbase Options:

Available in various wheelbase configurations, including short (approx. 2400 mm), long (approx. 2850 mm), and potentially extra-long versions.

Body Styles:

Available in various body styles including short-wheelbase (SWB) utility, long-wheelbase (LWB) station wagon, and potentially cab-chassis configurations.

Wheel Size Bolt Pattern:

Typically 16-inch or 15-inch wheels with a 5x130 bolt pattern.

Curb Weight Range:

Curb weight typically ranged from 1800 kg to over 2100 kg depending on configuration and powertrain.

Towing Capacity:

Towing capacity varies by model and configuration, typically substantial due to the robust chassis. Specific figures would be listed in the manual.

Gross Vehicle Weight Rating:

GVWR varies by configuration but is substantial, reflecting the vehicle's robust construction. Exact figures will be in the manual.

🛡️ Safety Features

Safety Ratings Era:

Safety standards and testing protocols were different in 1982. The W463's robust construction was its primary safety feature.

Passive Safety:

Strong body-on-frame construction, reinforced chassis, padded interior surfaces, lap and shoulder seat belts.

Seat Belts:

Includes details on seat belt inspection, maintenance, and replacement procedures.

Active Safety Features Era:

Limited; primary active safety was the driver's ability to engage differential locks for traction. ABS was not standard or widely available on early models.

💡 Technology Features

Infotainment Features Era:

Basic for its time. Likely featured an AM/FM radio, potentially with a cassette player. Analog gauges for instrumentation.

Driver Assistance Features:

None in the modern sense. Driver assistance was limited to the vehicle's inherent mechanical capabilities (e.g., locking differentials).

Connectivity Features:

No electronic connectivity features as known today.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type specified in the manual.

Engine Oil Spec:

Likely SAE 10W-40 or 15W-40 (API SF or SG classification) for gasoline engines, and SAE 15W-40 (API CD or CE classification) for diesel engines. Specific Mercedes-Benz specifications (e.g., MB 227.1 for diesel) would be detailed.

Coolant Spec:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specific MB approval numbers would be listed.

Transmission Fluid Auto:

Dexron II or equivalent automatic transmission fluid (ATF) for automatic transmissions.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Differential Fluid Spec:

API GL-5 gear oil for front, rear, and center differentials. Specific viscosity grade (e.g., 80W-90) would be detailed.

Common Wear Items:

Potential for rust, particularly on body panels and frame. Wear in suspension bushings, universal joints, and exhaust system components. Older diesel engines may experience injector pump or glow plug issues.

Engine Bolt Torques:

The manual will contain precise torque specifications for all critical engine components, such as cylinder head bolts, crankshaft main bearing caps, and connecting rod bolts.

Scheduled Maintenance Tasks:

Detailed schedules for oil changes, filter replacements (oil, fuel, air), spark plug replacement (gasoline), injection nozzle checks (diesel), valve adjustments, and other interval-based services.

Suspension Maintenance:

Covers servicing and replacement of springs, shock absorbers, control arms, bushings, and anti-roll bars. Includes wheel alignment specifications.

Ac Service:

Covers inspection, diagnosis, and repair of the air conditioning system, including refrigerant handling, compressor, condenser, evaporator, and climate control components.

📚 Vehicle History

Mercedes Heritage:

Mercedes-Benz has a long history of engineering robust and durable vehicles, including military vehicles which influenced the G-Class design.

G Class Evolution Context:

The 1982 model represents the early production years of the W460/W463 series, which was initially developed as a military vehicle and later adapted for civilian use. The W463 designation specifically began in 1989, but the manual covers a 1982 vehicle. This suggests the manual may be a precursor or cover vehicles that fall under the 'G-Wagen' lineage before the formal W463 designation. *Correction: The product title states W463 for 1982, which is an inconsistency as the W463 generation launched in 1989. This manual likely refers to the W460 series for the 1982 model year, as W463 did not exist then.*

W460 W463 Transition Note:

It is critical to note that the W463 chassis designation officially began in 1989. A 1982 model would be part of the W460 series. The product listing mentioning 'W463' for a 1982 model year suggests either an error in the product description or a colloquial use of the term for all G-Class vehicles of that era. This manual is therefore assumed to cover the W460 series for the 1982 model year.

Production Origins:

The G-Class has been manufactured by Mercedes-Benz, with assembly often conducted by Magna Steyr in Austria.

🏆 Awards & Recognition

Industry Recognition:

The G-Class is widely recognized for its durability, off-road prowess, and iconic design. It has achieved cult status among enthusiasts and off-roaders.