🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

W460

Specific Model Variant:

280GE

Model Years Covered:

Typically covers early to mid-production W460 models, including those with the 280GE engine. Specific years would need to be confirmed by the manual's content, but generally 1979-1991.

Engine Code:

M110 (for 280GE)

👋 Introduction

Vehicle Segment:

Luxury SUV, off-road utility vehicle.

Target Audience:

Enthusiasts, owners seeking to perform their own maintenance and repairs on a classic Mercedes-Benz G-Wagen.

Competitors Era:

Land Rover Defender, Toyota Land Cruiser, Jeep Wagoneer (during its production era).

Vehicle Philosophy:

Uncompromising off-road capability combined with Mercedes-Benz build quality and luxury.

Manual Value Proposition:

Provides detailed, authoritative technical guidance essential for maintaining and repairing the robust W460 G-Wagen.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English (assumed, standard for most widely distributed manuals)

Format:

PDF

Estimated Page Count:

Likely 500-1000+ pages, typical for comprehensive factory-level service manuals.

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, cylinder head, crankshaft, pistons, connecting rods, camshafts, valve train, timing.

Engine Fuel System:

Fuel injection system (Bosch K-Jetronic or similar for 280GE), fuel pump, injectors, pressure regulator, fuel lines.

Engine Ignition System:

Distributor, ignition coils, spark plugs, timing adjustment.

Engine Cooling System:

Radiator, water pump, thermostat, hoses, fan.

Engine Lubrication System:

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

Transmission Manual:

Disassembly, assembly, adjustment, shift mechanism, clutch, flywheel.

Transmission Automatic:

If applicable to specific 280GE variants, torque converter, valve body, planetary gears, fluid and filter service.

Drivetrain Front Axle:

Differential, axle shafts, CV joints, steering knuckles.

Drivetrain Rear Axle:

Differential, axle shafts, housing.

Drivetrain Transfer Case:

Operation, maintenance, repair, lubrication.

Suspension Front:

Coil springs, shock absorbers, control arms, bushings, sway bar.

Suspension Rear:

Leaf springs or coil springs (depending on variant), shock absorbers, trailing arms, Panhard rod, bushings.

Steering System:

Power steering pump, steering gearbox, steering column, tie rods, linkages.

Brake System:

Front disc brakes, rear drum brakes (or discs depending on variant), master cylinder, brake booster, proportioning valve, ABS (if equipped), lines, bleeding procedures.

Electrical System Battery:

Battery, charging system (alternator, voltage regulator).

Electrical System Lighting:

Headlights, taillights, interior lights, wiring diagrams.

Electrical System Instruments:

Dashboard gauges, warning lights, switchgear.

Electrical System Accessories:

Wipers, horn, power windows (if equipped), radio, HVAC blower motor.

Body Interior:

Seat removal, dashboard components, door panels, headliner, carpet.

Body Exterior:

Doors, hood, tailgate, fenders, bumpers, glass replacement, trim.

Body Chassis:

Frame inspection, rust repair, welding procedures.

HVAC System:

Heater core, evaporator, blower motor, refrigerant system (if A/C equipped), controls.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, lubrication points.

Troubleshooting:

Diagnostic charts for common symptoms, electrical fault finding with wiring diagrams.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation.

Diagnostics:

Engine performance diagnostics, electrical system testing.

Wiring Diagrams:

Comprehensive electrical schematics for various systems.

Torque Specifications:

Detailed torque values for critical fasteners.

Special Tools:

Identification of necessary special tools for specific procedures.

Depth Level:

Factory-level, comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Type:

PDF

Searchable:

Likely searchable text within the PDF, allowing for quick information retrieval.

Printable:

High-quality PDF format, designed for easy printing of specific sections or the entire manual.

Image Resolution:

High resolution for clear diagrams, illustrations, and schematics.

Format Type:

Digital (PDF)

Format Type:

Not applicable (digital format)

⚙️ Engine Specifications

Engine Name:

M110 Inline-6

Engine Type:

Naturally Aspirated, Overhead Camshaft (OHC), Dual Carburetor or Fuel Injection (depending on specific 280GE variant).

Displacement:

2.8 Liters (2746 cc)

Horsepower:

Approximately 150-160 hp (varies slightly by specific model year and configuration).

Torque:

Approximately 170-180 lb-ft (varies slightly).

Fuel Delivery:

Bosch K-Jetronic (CIS) Fuel Injection on later 280GE models. Earlier models might have dual Solex carburetors. Manual should cover the specific system.

Fuel Type:

Unleaded Gasoline (Octane rating as per manufacturer specification, typically 91 or higher).

Engine Control Unit:

If fuel injected, an electronic control unit (ECU) manages ignition and fuel delivery.

🔧 Transmission

Transmission Type Standard:

4-speed Manual Transmission (e.g., G460-XXXX model codes).

Transmission Type Optional:

4-speed Automatic Transmission (e.g., 722.3xx series).

Gear Ratios:

Specific gear ratios for both manual and automatic transmissions will be detailed in the manual.

Transfer Case:

Two-speed transfer case with selectable 4WD and locking differentials (center, rear, and sometimes front) are key features of the W460.

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, viscosity as per Mercedes-Benz specifications (e.g., SAE 75W-90).

Automatic Transmission Fluid:

Dexron II or equivalent specification fluid (e.g., MB 236.3).

📐 Dimensions

Wheelbase:

Short wheelbase (SWB): approx. 2400 mm; Long wheelbase (LWB): approx. 2850 mm. (Manual will confirm specific variants).

Length:

Varies significantly by body style (e.g., 2-door, 4-door, Wolf).

Curb Weight:

Approximately 1900-2200 kg, depending on configuration.

Gross Vehicle Weight Rating:

Typically around 2800-3000 kg.

🛡️ Safety Features

Crash Test Data:

While formal modern crash test data for early W460 models might be limited, the robust ladder frame construction and inherent weight provide a degree of passive safety. The manual may reference internal safety testing or structural integrity data.

Braking System:

Front disc brakes, rear drum brakes are standard. ABS was optional on later models. Manual will detail operation and diagnostics.

Frame Construction:

Heavy-duty ladder frame chassis, contributing to rigidity and occupant protection in off-road and moderate impact scenarios.

Seat Belts:

Three-point seat belts typically standard in the front, with lap belts or three-point belts in the rear depending on seating configuration.

💡 Technology Features

Audio System:

Basic analog radio/cassette players were common. The manual will cover the basic wiring and installation/removal of the head unit and speakers.

ABS:

Anti-lock Braking System was optional on later W460 models. The manual will cover its operation, diagnostics, and repair.

Wiring Harnesses:

Detailed wiring diagrams are a critical technology feature covered by the manual for troubleshooting electrical systems.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions. Manual will provide specific recommendations.

Filter Replacement Interval:

Oil filter with every oil change. Air filter and fuel filter typically every 20,000-40,000 km. Manual will specify.

Spark Plug Replacement:

Varies by plug type, generally 30,000-60,000 km. Manual will detail.

Engine Oil Type:

API SG/SH or higher, SAE 10W-40 or 15W-40 common. Specific viscosity recommended by MB.

Coolant Type:

Ethylene glycol-based coolant, typically MB 325.0 specification (green or blue).

Brake Fluid Type:

DOT 3 or DOT 4.

Common Wear Items:

Brake wear, exhaust system, universal joints, differential seals, engine mounts, suspension bushings, rust (especially on older chassis).

Engine Specific Issues:

Potential for oil leaks from the M110 engine, ignition system component failures, fuel distributor issues on K-Jetronic systems. Manual provides diagnostic steps.

📚 Vehicle History

Mercedes Benz Heritage:

Mercedes-Benz has a long history of producing robust, high-quality vehicles, including military and utility vehicles, which laid the groundwork for the G-Wagen's development.

W460 Development:

Developed in the 1970s for military and civilian use, emphasizing ruggedness, durability, and exceptional off-road capability. The 280GE was one of the early civilian variants.

Production Period W460:

1979-1991

Manufacturing Location:

Graz, Austria (by Magna Steyr, under contract for Mercedes-Benz).

🏆 Awards & Recognition

Off Road Accolades:

The G-Wagen, in its various forms, has consistently been recognized for its exceptional off-road prowess, often winning or performing exceptionally in international off-road challenges and military evaluations.

Longevity Awards:

The W460's design has proven remarkably enduring, with the G-Wagen platform continuing production for over four decades, a testament to its fundamental engineering. While specific awards for the early W460 might be scarce, its reputation for durability is its primary recognition.