🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Class

Chassis Code:

W460

Specific Model Variant:

280GE

Engine Code:

M102.938

👋 Introduction

Positioning:

The Mercedes-Benz G-Wagen (W460) is a legendary off-road vehicle, renowned for its ruggedness, durability, and distinctive utilitarian design. It has transcended its military origins to become a luxury icon, but its core engineering remains robust and requires specialized knowledge for maintenance and repair.

Comparison To Competitors:

Historically, the G-Wagen competed in the premium off-road segment against vehicles like the Range Rover, Jeep Grand Wagoneer, and Toyota Land Cruiser. Its unique combination of solid axles, differential locks, and Mercedes-Benz engineering set it apart. This manual provides the essential technical data to maintain this distinctiveness.

Manual Value Proposition:

This manual is the definitive resource for maintaining and repairing the Mercedes-Benz G-Wagen W460 280GE. Its comprehensiveness mirrors that used by Mercedes-Benz main dealers, ensuring accuracy and completeness for all service and repair tasks. It empowers owners and technicians with the knowledge to preserve the vehicle's iconic performance and longevity.

📋 Manual Details

Coverage Scope:

All areas of repair, maintenance, and diagnostics

Estimated Page Count:

Extensive (Exact number not specified, implies comprehensive dealership-level documentation)

Type:

Service and Repair Manual

Language:

English (Presumed, standard for international service manuals)

Format:

Digital Download (PDF, printable)

Searchability:

Searchable PDF format for efficient information retrieval.

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, crankshaft, pistons, camshafts, timing system, lubrication system, cooling system, fuel injection system (KE-Jetronic)

Engine Electrical:

Ignition system, starter motor, alternator, engine control unit (ECU) diagnostics and wiring diagrams

Transmission:

Manual and automatic transmission service, overhaul, clutch system, torque converter

Drivetrain:

Transfer case, differentials (front and rear), axles, driveshafts, locking differentials (if equipped)

Suspension:

Front and rear suspension components, springs, shock absorbers, bushings, steering linkage

Steering:

Power steering system, steering gearbox, steering column, steering wheel

Brakes:

Front and rear brake systems (disc/drum configurations), hydraulic lines, master cylinder, brake boosters, parking brake

Electrical System:

Lighting system, power windows, central locking, dashboard instruments, wiring diagrams for all circuits

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injection system components

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers

Body And Chassis:

Frame structure, body panels, doors, hoods, fenders, bumpers, interior trim, glass, seals

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault code interpretation, step-by-step troubleshooting guides

Repair And Overhaul:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems

Engine Rebuild:

Complete engine overhaul procedures, including specifications for machining and tolerances

Transmission Overhaul:

Detailed steps for disassembling, inspecting, and rebuilding both manual and automatic transmissions

Brake System Repair:

Pad and rotor replacement, caliper service, brake bleeding, hydraulic component replacement

Electrical Diagnostics:

Use of multimeters, oscilloscopes, and diagnostic scan tools; interpretation of wiring diagrams for fault finding

Bodywork And Paint:

Panel replacement, dent repair, rust prevention and repair, glass replacement

Torque Specifications:

Precise torque values for all critical fasteners and components

Diagnostic Tools:

Guidance on using standard automotive tools and potentially specialized Mercedes-Benz diagnostic equipment of the era.

Depth:

Dealership Level - Comprehensive and highly detailed, suitable for professional technicians and serious DIY enthusiasts

📊 Manual Specifications

Digital Format:

PDF

Printability:

High-resolution, printable pages for easy use in a workshop environment

Digital Binding:

N/A (Digital download; user can print and bind)

Digital Paper Type Recommendation:

Heavy-duty paper recommended for workshop use

Content Coverage:

Full coverage, designed for main dealer workshops, encompassing all aspects of vehicle service, repair, and diagnostics.

⚙️ Engine Specifications

Engine Family:

Mercedes-Benz M102

Engine Type:

Inline-4 Cylinder, Spark Ignition, Naturally Aspirated

Displacement:

2.8 Liters (2799 cc)

Bore X Stroke:

103.0 mm x 80.2 mm

Compression Ratio:

9.0:1 (Typical for M102.938)

Valve Train:

Overhead Camshaft (OHC), 2 valves per cylinder

Horsepower:

125 PS (92 kW) at 4750 rpm (Approximate, subject to market and specific tuning)

Torque:

235 Nm (173 lb-ft) at 2800 rpm (Approximate)

Fuel Delivery:

Bosch KE-Jetronic Fuel Injection (CIS-E)

Fuel Type:

Unleaded Gasoline (Octane rating appropriate for the era, typically 91 RON)

Ignition Type:

Electronic Ignition System

🔧 Transmission

Standard Transmission:

4-Speed Manual Transmission (Optional 5-Speed Manual in later W460 variants)

Optional Transmission:

3-Speed Automatic Transmission (e.g., 722.3 or 722.4)

Drivetrain Layout:

Four-Wheel Drive (4x4), permanent or part-time depending on specific configuration

Transfer Case:

Two-speed transfer case with optional locking differentials (center and rear, sometimes front)

📐 Dimensions

Wheelbase:

2850 mm (Standard wheelbase, for 280GE variant; shorter 2400mm and longer 3400mm also existed)

Length:

Approx. 4350 mm (for standard wheelbase variant)

Width:

Approx. 1760 mm

Height:

Approx. 1960 mm

Curb Weight:

Approx. 1950 kg (Varies by configuration)

Gross Vehicle Weight:

Approx. 2800 kg

🛡️ Safety Features

Crash Test Ratings:

N/A (Modern crash test standards were not prevalent during the W460's primary production era. Focus is on inherent structural integrity.)

Active Safety:

Four-wheel drive, excellent ground clearance, robust chassis, often equipped with locking differentials for enhanced traction.

Passive Safety:

Strong steel body and chassis construction, roll-over protection inherent in the design, seat belts.

💡 Technology Features

Infotainment Features:

Basic analog gauges, optional period-correct radio/cassette player. Focus is on functionality over features.

Driver Assistance Systems:

Minimal by modern standards. Primarily reliant on driver skill and the vehicle's inherent mechanical capabilities.

Connectivity Options:

None.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on usage. Refer to manual for exact specification.

Transmission Fluid Change:

Manual: Every 30,000-50,000 miles (50,000-80,000 km). Automatic: Every 30,000-40,000 miles (50,000-65,000 km). Consult manual.

Coolant Change:

Every 2-3 years or 30,000 miles (50,000 km).

Spark Plug Replacement:

Typically every 20,000-30,000 miles (30,000-50,000 km) for older ignition systems.

Engine Oil:

API SG or higher, viscosity typically SAE 10W-40 or 15W-40 (refer to manual for precise specification based on climate).

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Mercedes-Benz Specification 236.1 (e.g., Dexron II E or equivalent)

Coolant:

MB 325.0 or 326.0 (Ethylene Glycol based, typically a 50/50 mix with distilled water).

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

MB 236.3 (Dexron II or equivalent)

Common Wear Items:

Bushings (suspension, steering, drivetrain), exhaust system components, fuel pump, radiator, heater control valve, window seals.

Engine M102 Specifics:

Potential for oil leaks from valve cover gasket, timing chain wear over high mileage, injector seal issues on KE-Jetronic.

Rust Prone Areas:

Wheel arches, rocker panels, floor pans, rear crossmember, tailgate area.

📚 Vehicle History

Mercedes Benz Off Road Legacy:

Mercedes-Benz has a long history of producing robust vehicles, including military vehicles and tractors, which informed the development of the G-Wagen.

W460 Development:

The W460 was developed in the 1970s as a civilian and military utility vehicle. It was designed for extreme off-road capability, durability, and simplicity of maintenance.

W460 Production Years:

1979-1993 (with W461 and W463 succeeding it)

Manufacturing Location:

Graz, Austria (by Magna Steyr)

🏆 Awards & Recognition

Off Road Accolades:

While specific awards for the 280GE are not widely documented, the G-Wagen platform (W460/W461) is consistently recognized for its unmatched off-road prowess, durability, and reliability in extreme conditions, often by military and expedition users.