Vehicle Segment:
Luxury SUV / Off-Road Vehicle
Target Audience:
Owners seeking in-depth knowledge for maintenance, repair, and customization of their G-Class
Competitive Set 1996:
Land Rover Discovery, Jeep Grand Cherokee, Toyota Land Cruiser
Manual Advantage:
Vehicle-specific, dealership-level technical data, eliminating generic repair information
User Experience:
Easy-to-use PDF format, printable pages, searchable content, no physical wear and tear
Content Richness:
Diagrams, illustrations, wiring schematics, and comprehensive specifications
General Coverage:
All Models & All Repairs A-Z
Specific Model Coverage:
1996 Mercedes-Benz G-Class (W463)
Estimated Page Count:
Extensive (Implied, specific number not provided)
Type:
Service and Repair Manual
Engine Management:
Engine, Control System, Fuel Service Specifications, Emission Control, Intake Exhaust Cooling, Lube, Ignition Starting Charging
Drivetrain:
Auto Transmission, Clutch, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle Suspension
Chassis And Brakes:
Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering
Electrical And Body:
Electrical, Air Condition, Suppl Restraint System, Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/ Door, Exterior & Interior, Multiplex/ Can Communication
Maintenance And Servicing:
Complete step-by-step instructions for maintenance, service, and diagnosis
Repair And Rebuild:
Comprehensive repair procedures for all covered systems, from minor adjustments to major overhauls
Diagnostics:
Diagnostic procedures for identifying and resolving issues across all vehicle systems
Depth:
Factory highly detailed, exact same manual used by dealership technicians
Compatibility:
Windows Vista (32/64), XP, ME, 98, NT, 2000, and Mac
Software Requirements:
Adobe PDF Reader and Winzip (free online)
Printability:
All pages printable, with ability to blow-up images for enlarged copies
Paper Type Digital:
N/A (Digital format, but printable on any paper type)
Engine Options 1996:
Likely G 320 (M104 inline-6), G 300 Turbo Diesel (OM603 inline-5 turbo diesel), G 300 Diesel (OM603 inline-5 diesel), G 500 (M119 V8) - Manual will cover specific powertrains available in 1996
Horsepower Torque General:
Varies by engine; M104 approx. 208 hp, OM603 approx. 113 hp (turbo), M119 approx. 322 hp. Manual provides exact figures and performance data.
Fuel Delivery:
Fuel injection (Bosch KE-Jetronic or similar electronic injection depending on engine variant)
Fuel Type:
Unleaded gasoline (for petrol engines), Diesel fuel (for diesel engines)
Transmission Type Standard:
4-speed automatic (common for many W463 models)
Transmission Type Optional:
5-speed manual (less common, but available on some variants)
Drivetrain Layout:
4x4 Permanent (Four-wheel drive)
Transfer Case:
Two-speed transfer case with locking differentials (center, front, rear options)
Wheelbase Mm:
2850 (for standard wheelbase, specific variants may differ)
Overall Length Mm:
4215 (for standard wheelbase, specific variants may differ)
Overall Width Mm:
1760 (excluding mirrors)
Curb Weight Kg:
Approx. 2000-2300 kg (varies significantly by engine and equipment)
Gross Vehicle Weight Rating Kg:
Typically around 2800-3000 kg
Crash Test Results General:
Limited comprehensive official crash test data available for this era's specific W463 models in standardized formats like NHTSA/Euro NCAP. The vehicle's robust construction is a key safety feature.
Traction Control:
Available on some models/trims as ASR (Anti-Slip Regulation)
Antilock Brakes:
Standard ABS (Anti-lock Braking System)
Airbags:
Driver and passenger airbags (standard on most 1996 models)
Body Construction:
Heavy-duty, ladder frame chassis and steel body for exceptional durability and off-road capability.
Audio System:
Factory premium audio systems with AM/FM radio, cassette player, and optional CD changer. Manual covers head unit operation and basic troubleshooting.
Cruise Control:
Factory installed cruise control system (covered in manual).
Multiplex Communication:
Manual includes details on multiplex wiring and CAN communication protocols for diagnosed modules.
Oil Change Interval:
Typically every 7,500 - 10,000 miles (or annually), check manual for specific engine/oil type
Major Service Interval:
Refer to manual for specific mileage-based major service checks (e.g., 30,000, 60,000 miles).
Engine Oil Specification:
API SG/SH or higher, viscosity typically 0W-30, 5W-30, 5W-40, or 10W-40 depending on climate and engine (refer to manual for precise MB-Spec).
Coolant Specification:
Mercedes-Benz approved G 05 or G 06 coolant (silicate-free ethylene glycol based)
Brake Fluid Specification:
DOT 4 or DOT 3 brake fluid
Transmission Fluid Specification:
MB-Approval 236.x (e.g., 236.1 for older automatics). Manual specifies exact fluid.
Common Wear Items:
Rust on body panels (especially around wheel arches, sills), aging rubber seals and hoses, potential for ABS sensor issues, exhaust manifold leaks (on some engines).
Mechanical Durability:
Known for robust mechanical components, but like any older vehicle, regular maintenance is key to preventing issues.
Mercedes Benz Legacy:
Reputation for engineering excellence, durability, and off-road prowess dating back to military vehicles.
W463 Design Philosophy:
Developed as a robust, go-anywhere vehicle with a focus on utility, durability, and comfort, distinguishing it from more car-like SUVs.
1996 Update Context:
The 1996 model is part of the initial W463 generation, which saw gradual updates in engines and features, but retained its core rugged identity.
Manufacturing Location:
Graz, Austria (by Magna Steyr)
Off Road Capability Recognition:
Consistently recognized for its exceptional off-road capability and durability by automotive journalists and enthusiasts worldwide. Often used by military and expedition teams.
Reliability Perception:
High perception of long-term reliability and build quality, attributed to Mercedes-Benz's robust engineering.
