🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

W460

Model Variant:

300GD

Engine Code:

OM617

👋 Introduction

Positioning:

Targeted at Mercedes-Benz G-Wagen owners and independent repair shops specializing in classic or robust off-road vehicles. Positions itself as the definitive resource, rivaling official dealer documentation.

Competition:

Competes with official Mercedes-Benz workshop manuals (often harder to obtain and more expensive for older models) and other third-party repair guides. Emphasizes comprehensiveness and dealer-level information.

Dealer Use:

Indicates the manual contains the same level of detail and accuracy used by authorized Mercedes-Benz dealerships.

Instant Access:

Immediate download availability provides a significant advantage for urgent repair needs.

Flexibility:

Printable format allows users to create a physical copy tailored to their needs, enhancing usability in a workshop environment.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (Printable PDF)

Estimated Page Count:

Extensive (typically 1000+ pages for full Mercedes-Benz service manuals of this era)

📖 Manual Coverage

Engine:

Diesel engine (OM617) diagnostics, overhaul, and repair

Fuel System:

Injection pump, injectors, fuel lines, fuel tank, filtration

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure, lubrication passages

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler, pipes

Transmission:

Manual and automatic transmission service, repair, and overhaul (specific types to be detailed)

Drivetrain:

Transfer case, differentials, driveshafts, constant velocity (CV) joints, locking differentials (if equipped)

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, steering knuckles, control arms

Steering:

Power steering system, steering gearbox, steering linkage, tie rods, steering column

Brakes:

Disc and drum brake systems, brake calipers, rotors, pads, master cylinder, brake booster, parking brake

Electrical System:

Battery, alternator, starter, ignition system (for gasoline variants, though this is a diesel), wiring diagrams, fuses, relays, lighting

Body And Chassis:

Body panel removal and installation, frame repair, chassis components, doors, hood, tailgate

Interior:

Dashboard, seats, upholstery, trim panels, climate control system (HVAC)

Heating And Air Conditioning:

HVAC unit, blower motor, evaporator, condenser, refrigerant system

Diagnostics:

Troubleshooting guides, fault codes, diagnostic procedures

Routine Maintenance:

Oil changes, filter replacements, fluid checks, lubrication points

Component Overhaul:

Engine rebuild, transmission rebuild, differential overhaul

Adjustment Procedures:

Valve adjustments, timing belt/chain adjustments, brake adjustments

Troubleshooting:

Systematic diagnosis of common and uncommon problems

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems

Specifications:

Torque values, clearances, tolerances, fluid capacities

Depth Of Coverage:

Comprehensive: From routine maintenance to complete engine and drivetrain overhauls, including detailed diagnostic procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable, allowing for quick navigation

Printability:

Designed for home/shop printing, with individual sections printable as needed

Binding:

N/A (Digital Product - User prints and binds)

Recommended Paper:

Standard printer paper; heavier stock recommended for frequently used sections

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated Inline-Five Cylinder Diesel

Engine Code:

OM617.9xx (specific 'xx' depends on exact sub-model)

Displacement:

3.0 Liters (2998 cc)

Bore X Stroke:

90.9 mm x 92.4 mm

Compression Ratio:

21.0:1

Horsepower Approx:

80-88 hp @ 4000-4400 rpm (varies slightly by year/market)

Torque Approx:

135-145 lb-ft @ 2400-2800 rpm (varies slightly by year/market)

Injection System:

Bosch Mechanical Direct Injection

Fuel Type:

Diesel Fuel

Glow Plugs:

Pre-glow system for cold starting

🔧 Transmission

Transmission Type:

Typically paired with a 4-speed manual transmission or a 4-speed automatic transmission (e.g., 722.3/722.4).

Optional Transmission:

Availability of a 5-speed manual transmission might be found on later W460 models, but less common for the 300GD.

Transfer Case:

2-speed transfer case with selectable 4WD (4x4) and locking differentials (center, front, rear) as optional equipment or standard on certain trims.

Transmission Fluid Type:

Specific ATF (e.g., Dexron II or equivalent) for automatics; gear oil for manuals and transfer case/differentials.

📐 Dimensions

Wheelbase:

Approx. 2850 mm (112.2 inches) for long-wheelbase models

Body Styles:

Offered in various body styles including Station Wagon (SW), Cabriolet (soft top), and Panel Van.

Curb Weight:

Approx. 2000-2200 kg (4400-4850 lbs) depending on configuration.

🛡️ Safety Features

Crash Testing:

While formal crash ratings from modern agencies were not as prevalent or standardized during the W460's production, the vehicle's robust body-on-frame construction provided inherent structural integrity. Specific tests and ratings would be limited for this era.

Active Safety:

Four-wheel disc brakes (often standard on later models), locking differentials for enhanced traction.

Passive Safety:

Reinforced chassis and body structure, seat belts (likely lap belts in earlier models, 3-point in later versions), minimal driver aids typical for the era.

💡 Technology Features

Infotainment System:

Basic for its era: Analog gauges, AM/FM radio, and potentially a cassette player. No modern digital displays or integrated navigation.

Driver Assistance Features:

None in the modern sense. Features focused on off-road capability (locking differentials) rather than electronic driver aids.

Connectivity:

No onboard connectivity or Bluetooth. Designed for functional utility.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions.

Air Filter Replacement:

Inspect every 5,000 miles (8,000 km), replace as needed or annually.

Fuel Filter Replacement:

Typically every 15,000 - 20,000 miles (24,000 - 32,000 km).

Coolant Change:

Every 2-3 years or as recommended by the manual.

Engine Oil Spec:

API CD or CE classification; SAE 10W-40 or 15W-40 is common, check manual for specific temperature range recommendations.

Engine Oil Capacity:

Approx. 7.5 liters (7.9 US quarts) with filter change.

Coolant Spec:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. MB 325.0 or equivalent.

Transmission Fluid Auto:

MB Automatic Transmission Fluid (ATF) specification 236.1 or equivalent (e.g., Dexron II/III, check manual for exact type).

Transfer Case Fluid:

API GL-4 or GL-5 gear oil, SAE 80W-90.

Differential Fluid:

API GL-5 gear oil, SAE 80W-90 or 85W-140.

Common Wear Items:

Brake components (pads, rotors), suspension bushings, exhaust system rust, glow plug issues, vacuum lines, power steering hoses, radiator and coolant hoses.

Om617 Engine Longevity:

Known for exceptional durability, but can suffer from oil leaks (valve cover gasket, oil cooler seals) and injector pump wear over time.

Chassis Corrosion:

Prone to rust on frame rails, rocker panels, and wheel arches, especially in areas exposed to salt.

📚 Vehicle History

Mercedes Benz Heritage:

Mercedes-Benz has a long history of producing robust, reliable, and high-quality vehicles, particularly in the commercial and utility sectors. The G-Wagen was born from a requirement for a military vehicle.

W460 Introduction:

The W460 series was introduced in 1979 as a utilitarian off-road vehicle, designed for military and civilian use requiring extreme durability and off-road capability.

W460 Development:

Developed in collaboration with Steyr-Daimler-Puch in Austria. It was built to be rugged, capable, and easily repairable in remote locations.

300Gd Specifics:

The 300GD variant utilized the proven OM617 naturally aspirated diesel engine, known for its longevity and fuel efficiency (relative to its performance).

Production Period:

The W460 series was produced from 1979 to 1992, with the 300GD being a prominent and long-running model within this generation.

Manufacturing Location:

Graz, Austria by Steyr-Daimler-Puch (later Magna Steyr).

🏆 Awards & Recognition

Off Road Recognition:

Universally recognized for its exceptional off-road prowess and go-anywhere capability. Often cited as a benchmark for ruggedness.

Military Service:

Widely used by military forces worldwide, a testament to its durability, reliability, and serviceability under extreme conditions.

Reliability Reputation:

High reputation for mechanical reliability and longevity, particularly the OM617 diesel engine, when properly maintained.