Mercedes Benz G wagen 460 280GE Factory Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Engine Variant: 280GE Codes Internal Model Code: W460 👋 Introduction Market Position Segment: Premium, rugged, off-road capable SUV. Target...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

G-Wagen

Chassis Code:

Engine Variant:

280GE

Codes

Internal Model Code:

👋 Introduction

Market Position

Segment:

Premium, rugged, off-road capable SUV.

Target Audience:

Off-road enthusiasts, luxury SUV buyers seeking durability and capability, collectors of classic Mercedes-Benz vehicles.

Competitive Analysis

Competitors Era:

Land Rover Defender, Toyota Land Cruiser (J60/J70 series), Range Rover Classic.

Key Features

Design Philosophy:

Robust body-on-frame construction, exceptional off-road capability, legendary durability and build quality.

Unique Selling Points:

Triple locking differentials (optional), coil spring suspension, solid axles, exceptional approach/departure angles.

Manual Value Proposition

Benefit To Owner:

Enables owners to perform all necessary maintenance and repairs, reducing reliance on specialized (and potentially expensive) service centers, and preserving the vehicle's longevity and capability.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive factory service and repair for the Mercedes-Benz G-Wagen 460 series, specifically the 280GE variant.

Page Count

Estimated Pages:

Hundreds (precise count not specified, but implied to be extensive for factory manual).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (Implied for most international sales)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, and specifications for the M102 2.8L inline-6 gasoline engine.

Fuel System:

K-Jetronic (CIS) fuel injection system, fuel pump, injectors, pressure regulator, air flow meter, cold start system, and emissions control.

Ignition System:

Ignition timing, distributor, coil, spark plugs, and electronic control unit (if applicable).

Cooling System:

Radiator, fan, water pump, thermostat, hoses, and coolant specifications.

Lubrication System:

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

Exhaust System:

Exhaust manifolds, catalytic converter (if equipped), mufflers, and emissions components.

Transmission:

Manual and automatic transmission overhaul, repair, fluid specifications, and troubleshooting. Covers both 4-speed and 5-speed manual transmissions, and 4-speed automatic transmissions (e.g., 722.3).

Drivetrain:

Front and rear differentials, transfer case (including locking mechanisms), driveshafts, CV joints, and hub assemblies.

Suspension:

Front and rear suspension components, springs, shock absorbers, bushings, ball joints, tie rod ends, and alignment specifications.

Steering:

Power steering system, steering gearbox, steering column, and related components.

Brakes:

Front and rear brake systems (disc brakes), brake calipers, master cylinder, brake lines, parking brake, ABS components (if equipped), and fluid specifications.

Electrical System:

Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, and accessory circuits.

Climate Control:

Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, and troubleshooting.

Body And Chassis:

Body panel removal and installation, frame inspection, doors, windows, seats, and interior trim.

Wheels And Tires:

Wheel specifications, tire sizes, and mounting procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication points, and belt inspections.

Engine Repair:

Engine assembly/disassembly, piston/ring replacement, cylinder head service, valve adjustments, crankshaft/camshaft service.

Transmission Repair:

Clutch replacement (manual), torque converter service (automatic), gear set replacement, seal and gasket replacement.

Brake Service:

Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper overhaul, bleeding procedures.

Suspension And Steering Repair:

Component replacement (shocks, springs, ball joints, tie rods), alignment procedures.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, component testing, and symptom-based diagnostics.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues across all vehicle systems.

Torque Specifications:

Detailed torque values for all critical fasteners across various systems.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Complete factory-level technical information, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Printable, allowing users to reproduce specific sections or the entire manual.

Binding Type

Binding Method:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

2.8 Liters (2799 cc)

Bore X Stroke:

86.0 mm x 80.25 mm

Compression Ratio:

8.3:1 (typical)

Performance

Horsepower:

Approx. 150 PS (148 hp) @ 5250 rpm (varies slightly by market and year)

Torque:

Approx. 230 Nm (170 lb-ft) @ 3250 rpm (varies slightly by market and year)

Fuel System

Injection System:

Bosch K-Jetronic (Continuous Injection System - CIS)

Fuel Type:

Unleaded Gasoline (RON 91 / Octane 87 recommended)

Cooling System

Coolant Capacity:

Approx. 10.5 Liters (with heater)

Lubrication System

Oil Capacity:

Approx. 7.5 Liters (with filter) - Check manual for exact specification.

Recommended Oil Viscosity:

10W-40 or 15W-40 (API SG or higher, consult manual for specific MB approval).

🔧 Transmission

Standard

Transmission Type:

4-Speed Manual (e.g., G320 manual transmission)

Optional

Transmission Type:

4-Speed Automatic (e.g., 722.3)

Features

Gear Ratios Manual:

Refer to manual for specific ratios, typically includes low-range gearing.

Gear Ratios Automatic:

Refer to manual for specific ratios, typically includes low-range gearing.

Fluid Capacity

Manual Transmission Oil:

Approx. 2.0 Liters (GL-4 or GL-5, consult manual for exact spec).

Automatic Transmission Fluid:

Approx. 8.0 Liters (Pan & Converter - ATF Dexron III or equivalent, consult manual for exact spec).

📐 Dimensions

Exterior

Wheelbase:

2400 mm (Standard Wheelbase), 2850 mm (Long Wheelbase)

Overall Length:

Approx. 4000 mm (SWB) / 4340 mm (LWB)

Overall Width:

Approx. 1780 mm

Overall Height:

Approx. 1960 mm

Weights

Curb Weight:

Approx. 1900 - 2100 kg (depending on configuration)

Gross Vehicle Weight Rating:

Approx. 2800 kg

Wheels And Tires

Standard Tire Size:

205 R16, 215/75 R15 (common)

Wheel Bolt Pattern:

5 x 112 mm

Wheel Size:

15 or 16 inch

🛡️ Safety Features

Ratings

Crash Test Results:

Limited official crash test data available for this era of W460. Focus on inherent structural integrity.

Active Features

Optional on some later models, but not standard on early W460 280GE.

Differential Locks:

Optional front, center, and rear locking differentials provide exceptional off-road traction and safety.

Passive Features

Seatbelts:

Standard front seatbelts; rear seatbelts vary by configuration and market. Manual will detail proper installation and adjustment.

Chassis Construction:

Body-on-frame construction with a rigid ladder chassis for durability.

💡 Technology Features

Infotainment

Audio System:

Basic factory AM/FM radio with cassette player. Aftermarket upgrades are common. Manual covers factory wiring.

Driver Assistance

As mentioned, optional on later models. Not a significant feature for most W460 models.

Connectivity

Factory Options:

Limited to basic vehicle systems. No modern connectivity features (Bluetooth, USB, etc.) from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 10,000 km or annually (consult manual for specific mileage and driving conditions).

Filter Replacement:

Oil filter at every oil change. Air filter and fuel filter as per manual's schedule (typically every 20,000 - 40,000 km).

Spark Plug Replacement:

Typically every 20,000 - 40,000 km, depending on plug type (consult manual).

Transmission Fluid Change:

Manual: Every 40,000 - 60,000 km. Automatic: Every 50,000 - 80,000 km (or as specified in the manual).

Brake Fluid Change:

Every 2 years, regardless of mileage, to prevent moisture absorption.

Fluid Specifications

Engine Oil Spec:

Refer to manual for specific Mercedes-Benz approval numbers (e.g., MB-Approval 228.1 or 228.3 for diesel, 229.1 for gasoline, though 10W-40 SG is a common alternative). Manual will specify the correct type.

Coolant Spec:

Glysantin G05 (silicate-free) or equivalent, mixed 50/50 with distilled water. Consult manual for exact type and MB approval.

Power Steering Fluid:

Pentosin CHF 11S or equivalent hydraulic fluid (consult manual for correct specification).

Brake Fluid:

DOT 3 or DOT 4 (consult manual for specific requirement).

Known Issues

Common Wear Items:

Bushings (suspension, body mounts), exhaust system, K-Jetronic fuel distributor, fuel pumps, ignition components, heater control valves.

Corrosion Prone Areas:

Wheel arches, rocker panels, tailgate lower edge, frame outriggers (especially in rust-belt regions). Manual will detail inspection points.

📚 Vehicle History

Brand Heritage

Manufacturer Legacy:

Mercedes-Benz has a long history of producing robust and durable vehicles, particularly for military and off-road applications, dating back to its origins.

Model Evolution

G Wagen Concept:

Developed in response to a request from the German military in the 1970s, prioritizing off-road capability, durability, and versatility. The W460 was the civilian and initial military version.

W460 Production Years:

1979 - 1993

280Ge Introduction:

Introduced in 1979 as a key gasoline engine option for the W460 chassis.

Production

Manufacturing Location:

Graz, Austria (Magna Steyr facility, contracted by Mercedes-Benz)

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

The G-Wagen series, including the W460, is universally recognized for its superior off-road capabilities and durability, often winning comparisons against contemporary SUVs.

Military Endorsement:

Widely adopted by military forces worldwide, a testament to its robustness and reliability under demanding conditions.