🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

W460

Production Period:

1979-1993

👋 Introduction

Positioning:

The definitive guide for maintaining and repairing the iconic Mercedes-Benz W460 G-Wagen, a vehicle renowned for its off-road capability and rugged durability.

Comparison:

Surpasses generic Haynes or Chilton manuals by providing factory-level detail and accuracy, essential for the specific engineering of Mercedes-Benz vehicles. Competes with official MB data but offers a more accessible digital format.

Unique Selling Points:

Comprehensive coverage of all W460 variants, main dealer level accuracy, detailed diagrams and troubleshooting, accessibility for digital users.

📋 Manual Details

Manual Type:

Comprehensive Workshop/Maintenance Manual

Coverage Areas:

All areas of repair and maintenance for Mercedes-Benz G-Wagen W460 series.

Intended Audience:

Main Dealers, Professional Technicians, Enthusiast Owners

Format:

Digital (Downloadable)

Printable:

Yes

Language:

English

📖 Manual Coverage

Engine:

Complete coverage of all W460 engine variants including M102, OM616, OM617, and OM602. Includes disassembly, assembly, diagnostics, and repair for cylinder head, block, fuel injection, lubrication, cooling, and exhaust systems.

Transmission:

Detailed procedures for manual (4-speed and 5-speed) and automatic (3-speed and 4-speed) transmissions. Covers gear engagement, clutch operation, torque converter, transmission overhaul, and troubleshooting.

Drivetrain:

In-depth coverage of front and rear axles, differential locks, transfer case (2-speed with center differential lock), driveshafts, and CV joints. Includes adjustment, lubrication, and repair procedures.

Suspension And Steering:

Covers front and rear leaf spring suspension (some later models had coil springs), shock absorbers, kingpins, steering box, drag links, tie rods, and steering damper. Includes alignment specifications and troubleshooting.

Brakes:

Detailed information on front disc brakes and rear drum brakes (or optional rear discs on some models). Includes brake caliper overhaul, master cylinder replacement, brake bleeding procedures, parking brake system, and hydraulic circuit diagrams.

Electrical System:

Comprehensive wiring diagrams for all model years and configurations. Covers starting system, charging system (alternator), ignition system, lighting, instruments, power windows, wipers, horn, and radio pre-wiring.

Body And Chassis:

Includes body panel removal and installation, door mechanisms, seat adjustments, roof lining, underbody protection, rust prevention, and frame straightening procedures. Covers various body styles: Station Wagon, Cabriolet, Panel Van.

Heating And Air Conditioning:

Details on heater core, blower motor, ventilation systems, and optional air conditioning system components and servicing.

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements, fluid checks, lubrication points, belt inspections, brake adjustments, and more.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and uncommon issues, fault code interpretation (where applicable), and systematic diagnostic approaches for all major systems.

Repair Procedures:

Comprehensive, illustrated instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Adjustment Procedures:

Precise instructions for valve adjustments, ignition timing, carburetor/fuel injection adjustments, clutch play, brake pedal free play, and headlight aiming.

Troubleshooting Guides:

Specific troubleshooting trees for engine performance issues, electrical faults, transmission problems, braking system anomalies, and more.

Depth:

Expert-level. Covers everything from routine fluid changes and filter replacements to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs.

Detail Level:

Highly detailed with torque specifications, clearances, special tool requirements, and exploded diagrams.

📊 Manual Specifications

File Type:

PDF (likely)

Searchability:

Likely text-searchable PDF for easy information retrieval.

Printability:

Designed for high-quality printing of individual pages or sections.

Binding Type:

N/A (Digital Download - Print as needed)

Paper Type Recommendation:

Standard printer paper for most sections; heavier stock recommended for frequently referenced pages or covers.

⚙️ Engine Specifications

Gasoline Engines:

M102 series (2.0L, 2.3L, 2.3L-4 inline-4), M110 series (2.8L inline-6 on early models), M111 series (2.3L supercharged on some later W460 variants, though more common in W463).

Diesel Engines:

OM616 series (2.4L inline-4 diesel), OM617 series (3.0L inline-5 diesel), OM602 series (2.9L inline-5 diesel - common on later W460 models).

2.3L M102:

Approx. 90-125 HP, 120-145 lb-ft torque (variant dependent).

3.0L Om617:

Approx. 78-85 HP, 125-134 lb-ft torque.

2.9L Om602:

Approx. 94-108 HP, 140-160 lb-ft torque.

Gasoline Fuel System:

Carburetor (e.g., Solex, Zenith) on early models, Bosch K-Jetronic (CIS) or KE-Jetronic (CIS-E) fuel injection on later models.

Diesel Fuel System:

Mechanical Injection Pumps (e.g., Bosch VE or similar).

Cooling Type:

Pressurized liquid cooling system with engine-driven fan or viscous coupling fan.

Oil Type Recommendation:

Refer to manual for specific model year and engine; typically API CD/SF or higher diesel oils, and API SG/SH for gasoline. Viscosity grades like 15W-40, 20W-50, or 10W-40 depending on climate.

🔧 Transmission

Manual Options:

4-speed (e.g., ST4-100) and 5-speed (e.g., G3/24, G3/28) manual transmissions.

Automatic Options:

3-speed (e.g., 3HP22) and 4-speed (e.g., 722.3, 722.4) automatic transmissions.

Transfer Case:

2-speed transfer case with selectable 4WD and center differential lock (CDL) as standard on most models.

Manual Transmission Fluid:

Refer to manual for specific MB specifications (e.g., MB 235.1 or 235.5 gear oil, typically SAE 80W-90 or 85W-90 GL-4/GL-5).

Automatic Transmission Fluid:

Refer to manual for specific MB specifications (e.g., MB 236.6 or ATF Dexron II/III compatible fluids).

📐 Dimensions

Wheelbase:

Short: 2400 mm (94.5 in), Long: 2850 mm (112.2 in)

Length:

Short: ~4000 mm (157.5 in), Long: ~4600 mm (181.1 in) (varies by body style)

Width:

~1760 mm (69.3 in)

Height:

~1960 mm (77.2 in) (varies by body style)

Curb Weight:

Approx. 1900 - 2200 kg (4189 - 4850 lbs) depending on configuration.

Gross Vehicle Weight:

Up to 3000 kg (6614 lbs) or more for specific models.

Standard Tire Sizes:

Commonly 7.50R16, 205R16, 235/75R15, 255/75R15 (variant dependent).

Bolt Pattern:

5x130mm

Wheel Offset:

ET30 to ET45 typical range.

🛡️ Safety Features

Crash Test Data:

Limited formal crash test data from contemporary agencies compared to modern vehicles. However, its robust chassis construction and mechanical systems were designed for durability.

Standard Safety Features:

Four-wheel drive, locking differentials (center, and optional front/rear), strong frame construction, robust braking system.

Passive Safety:

Seat belts, reinforced body structure, steel construction.

💡 Technology Features

Original Infotainment:

Basic AM/FM radio or cassette player. Optional power antenna. Minimal integration by modern standards.

Original Driver Assistance:

No electronic driver assistance systems as understood today. Relies on mechanical systems and driver skill.

Original Connectivity:

None. Vehicle systems are entirely mechanical and electrical.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on engine type and driving conditions. Refer to manual for specific engine recommendations.

Air Filter Replacement:

Every 20,000-40,000 km (12,000-24,000 miles) or as needed based on driving environment.

Fuel Filter Replacement:

Diesel: Every 20,000-30,000 km (12,000-18,000 miles). Gasoline: Refer to manual, often with fuel injection service.

Transmission Fluid Change:

Manual: Inspect periodically, change every 50,000-100,000 km (30,000-60,000 miles). Automatic: Every 40,000-60,000 km (24,000-36,000 miles).

Coolant Type:

Ethylene glycol-based antifreeze (e.g., MB 325.0, 325.2, or equivalent G48/G11 standard). 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Refer to manual for MB specification (likely MB 236.3 or a Dexron type fluid).

Common Faults Diesel:

Glow plug failures, injection pump seal leaks, exhaust manifold cracks (OM617), injector line leaks.

Common Faults Gasoline:

Carburetor tuning issues, K-Jetronic fuel distributor problems, vacuum leaks, ignition coil failure, timing chain wear (M102).

Common Faults Chassis:

Rust (especially frame, wheel arches, rocker panels), worn leaf springs, kingpin wear, universal joint wear, differential seal leaks.

Common Faults Electrical:

Degraded wiring insulation (due to age), fuse box corrosion, headlight switch failure, alternator bearing noise.

📚 Vehicle History

Brand Legacy:

Mercedes-Benz, established in 1926, is synonymous with automotive engineering excellence, luxury, and durability. The G-Wagen embodies this heritage with its robust, utilitarian design.

W460 Development:

Developed in the 1970s as a military vehicle and civilian off-roader, the W460 established the G-Wagen's iconic look and legendary off-road prowess. It was built to be extremely durable and adaptable to various terrains and roles.

W460 Variants:

Offered in numerous body styles including 3-door Short Wheelbase (SWB), 5-door Long Wheelbase (LWB) Station Wagon, Cabriolet, and Panel Van. Chassis were also available for custom bodywork.

Manufacturing Location:

Graz, Austria (contract manufacturing by Magna Steyr).

Production Volume:

Significant production volumes over its multi-decade lifespan, with the W460 being the foundation for all subsequent G-Wagen generations.

🏆 Awards & Recognition

Off Road Awards:

Consistently recognized for unparalleled off-road capability, often winning or placing highly in competitive off-road events and expeditions.

Durability Awards:

Awarded for extreme durability and longevity, with many W460 models still in active service after decades of rigorous use.

Military Certifications:

Adopted by numerous military forces worldwide, demonstrating its adherence to stringent performance and reliability standards.