🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Class

Chassis Code:

W463

👋 Introduction

Positioning:

The Mercedes-Benz G-Class (W463) is a legendary luxury off-road vehicle, renowned for its robust build, off-road capability, and enduring design. This manual caters to owners and independent repair facilities seeking to maintain and repair these iconic vehicles.

Competitors In Era:

While the G-Class occupied a unique premium niche, direct competitors in terms of luxury off-road capability and robust build from this era included vehicles like the Land Rover Range Rover, Toyota Land Cruiser (specific trims), and some high-end Jeep Grand Cherokee models.

Vehicle Attributes:

Body-on-frame construction, permanent four-wheel drive, locking differentials (center, rear, optional front), high ground clearance, robust and durable engineering.

Value:

Empowers owners to perform their own maintenance and repairs, significantly reducing dealership service costs. Provides detailed, step-by-step instructions with visual aids for complex procedures.

📋 Manual Details

Model Years Covered:

1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Engine Variants Covered:

All engine variants, including petrol (e.g., M103, M104, M112, M113) and diesel (e.g., OM602, OM603, OM606, OM612, OM647)

Trim Levels Covered:

All trim levels, including Classic, Elegance, Avantgarde, AMG variants (e.g., G55 AMG)

Transmission Types Covered:

All transmission types, including 4-speed automatic (e.g., 722.4, 722.6), 5-speed automatic, and manual transmissions

Estimated Page Count:

Likely exceeding 2,000 pages, typical for comprehensive workshop manuals of this scope and duration

Type:

Complete Workshop Service and Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

Accessibility:

Instant delivery via email, allowing immediate access for troubleshooting and repair planning.

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, cooling system, lubrication system

Engine Management:

Fuel injection systems (e.g., KE-Jetronic, EIS, ME-SFI), ignition systems, emission control systems, engine control unit (ECU) diagnostics

Transmission Drivetrain:

Automatic transmission overhaul, manual transmission overhaul, transfer case, drive shafts, differentials, axles, hubs

Suspension Steering:

Front and rear suspension components (springs, shocks, control arms, bushings), power steering system, steering gear, steering column

Brakes:

Brake system components (calipers, rotors, pads, master cylinder, brake booster), ABS system (control module, sensors, hydraulic unit), parking brake

Electrical System:

Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), fuses, relays, wiring harnesses, grounds

Body Chassis:

Body construction, frame, doors, hood, tailgate, bumpers, glass, seals, corrosion protection

HVAC:

Heating, ventilation, and air conditioning (HVAC) system components, refrigerant circuits, climate control unit

Interior:

Seats, dashboard, door panels, headliner, interior trim, seat belts, airbags

Wheels Tires:

Wheel bearing replacement, tire pressure monitoring system (TPMS) for later models, wheel and tire specifications, alignment procedures.

Body Hardware:

Door lock mechanisms, window regulators, mirror adjustments, exterior trim panel removal and installation.

Scheduled Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, fluid level checks and top-offs

Routine Repairs:

Brake pad replacement, bulb replacement, wiper blade replacement, battery testing and replacement, belt replacement

Major Repairs:

Engine overhaul, transmission rebuild, clutch replacement (manual), differential overhaul, suspension component replacement

Diagnostics Troubleshooting:

Step-by-step diagnostic procedures, fault code interpretation, wiring diagrams, component testing

Special Tools:

Identification and usage of specialized tools required for specific repair procedures

Torquing Specifications:

Precise torque values for all critical fasteners (engine, chassis, suspension, wheels)

Troubleshooting Charts:

Detailed symptom-to-cause troubleshooting charts for common drivability, electrical, and mechanical issues.

Recalibration Procedures:

Information on recalibrating electronic modules after component replacement (e.g., ABS module, engine control unit).

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics and bodywork repairs.

Diagnostic Tools:

Covers procedures that may require Mercedes-Benz specific diagnostic tools (e.g., Star Diagnosis) or generic OBD-II scanners.

Manual Purpose:

Serves as a comprehensive repair and diagnostic guide for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

Compatibility:

Compatible with all PC & MAC computers, tablets, and mobile phones. Requires Adobe Reader (free download).

Searchability:

PDF format typically allows for text searching of keywords, greatly aiding in finding specific information quickly.

Quality:

High quality, enabling clear printing of individual pages or entire chapters.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

Multiple engine options across the model years, including inline-6 petrol (e.g., 3.0L M103, 3.2L M104), V6 petrol (e.g., 3.2L M112), V8 petrol (e.g., 4.2L M119, 5.0L M113), inline-6 diesel (e.g., 3.0L OM603, 3.5L OM603), inline-5 diesel (e.g., 2.9L OM602), inline-5 turbodiesel (e.g., 2.9L OM602, 2.7L OM612), inline-5 turbodiesel (e.g., 2.7L OM612), inline-5 turbodiesel (e.g., 3.2L OM647).

Engine Codes Examples:

Examples include M103.972 (3.0L petrol), M113.961 (5.0L V8 petrol), OM602.980 (2.9L diesel), OM647.961 (2.7L CDI diesel).

Horsepower Torque Range:

Horsepower typically ranging from 110 hp (diesel) to over 350 hp (AMG models). Torque figures also vary significantly based on engine displacement and forced induction.

Injection Type:

Varies by engine; includes mechanical fuel injection (e.g., Bosch KE-Jetronic), electronic fuel injection (EFI), and common rail diesel injection (CRDI) in later models.

Emission Controls:

Includes information on catalytic converters, oxygen sensors, EGR (Exhaust Gas Recirculation) systems, and evaporative emission control (EVAP) systems as applicable to specific engine variants.

🔧 Transmission

Standard Transmission:

Primarily 4-speed and 5-speed automatic transmissions. Some early models and specific variants were available with a 5-speed manual transmission.

Optional Transmission:

Not typically applicable as transmission choice was often tied to engine/trim, but different automatic transmission families (e.g., 722.4 vs. 722.6) were offered.

Transfer Case Features:

Permanent all-wheel drive with a lockable center differential and a lockable rear differential as standard or optional features depending on trim and year.

Automatic Transmission Codes:

Examples include 722.4, 722.6 (5-speed automatic).

📐 Dimensions

Body Styles:

Offered in various body styles including 3-door short-wheelbase, 5-door long-wheelbase station wagon, and cabriolet.

Curb Weight Range:

Curb weights typically range from approximately 2,000 kg to 2,500 kg or more, depending on engine, equipment, and body style.

🛡️ Safety Features

Crash Test Ratings:

As this era predates widespread standardized crash testing for such vehicles, specific NCAP or IIHS ratings may not be readily available. The G-Class is known for its robust ladder frame and durable construction.

Driver Assistance:

Later models within this range began incorporating ABS (Anti-lock Braking System). Electronic Traction System (ETS) and Electronic Stability Program (ESP) were introduced in later years.

Restraints:

Front airbags for driver and passenger, three-point seat belts for all occupants, and side-impact protection beams.

💡 Technology Features

Audio System:

Varies by year and trim. Features could include AM/FM radio, CD players, cassette players, and premium sound systems from brands like Bose or Becker. Later models saw the introduction of more advanced head units with navigation and greater connectivity options.

Cruise Control:

Cruise control was a common feature on most models.

Telematics:

Early models had limited connectivity. Later models may offer basic phone integration or optional telematics systems.

🔧 Maintenance

Oil Change Interval:

Typically 10,000 to 15,000 km or 12 months, whichever comes first. Consult specific engine requirements in the manual.

Transmission Fluid Interval:

Automatic transmission fluid and filter changes are often recommended every 60,000 km. Manual transmission fluid changes may be less frequent.

Spark Plug Replacement:

Intervals vary by engine type (e.g., conventional, platinum, iridium), typically ranging from 30,000 km to 100,000 km. Manual will specify exact type and interval.

Engine Oil:

Varies by engine. Typically synthetic or semi-synthetic oils meeting MB-Approval 229.1, 229.3, or 229.5 specifications. Consult manual for specific viscosity (e.g., 5W-40, 0W-40).

Transmission Fluid Auto:

Automatic transmission fluid (ATF) meeting MB-Approval 236.x specifications. Specific types like Dexron III or MB 236.10/236.12 may be required depending on transmission type.

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors, typically meeting MB-Approval 325.0 or 325.2. Usually a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 brake fluid.

Common Wear Items:

Ball joints, tie rod ends, control arm bushings, wheel bearings, driveshaft flex discs (guibos), catalytic converters (older models), ABS sensors.

Electrical Gremlins:

While robust, older vehicles can experience issues with window regulators, central locking systems, and aging wiring harnesses. Climate control units can also be a point of failure.

Body Corrosion:

Corrosion can occur in common areas like wheel arches, door bottoms, and chassis components, particularly in regions with harsh winters or salt exposure.

Engine Misfires:

Can be caused by ignition coil issues, spark plug failure, fuel injector problems, or vacuum leaks, all of which are covered in diagnostic procedures.

📚 Vehicle History

Mercedes Benz Offroad:

Mercedes-Benz has a long history of producing robust vehicles, with the G-Wagen's lineage tracing back to military development in the 1970s.

W463 Development:

The W463 generation, introduced in 1989, represented a significant update with more luxurious appointments, a revised interior, and updated engine and transmission options compared to its W460 predecessor. This generation maintained its core off-road prowess while embracing greater on-road comfort.

Manufacturing Location:

Graz, Austria (by Magna Steyr)

🏆 Awards & Recognition

Offroad Acclaim:

The G-Class is globally recognized for its exceptional off-road capabilities and has been used by numerous militaries and in demanding expeditions, earning it a reputation as one of the most capable production off-road vehicles.