🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G500

Year:

2003

Chassis Code:

W463

Engine Code:

M113.961

👋 Introduction

Positioning:

The Mercedes-Benz G500 is a highly capable luxury off-road SUV, known for its robust construction, legendary G-Wagen heritage, and powerful V8 engine. This manual caters to owners and independent repair facilities needing in-depth information for maintenance and repair.

Competitors:

Competes with other high-end SUVs like the Land Rover Range Rover, Lexus LX, and Cadillac Escalade, though the G-Wagen occupies a unique niche focused on off-road prowess and military-derived robustness.

Vehicle Features:

Permanent all-wheel drive, three lockable differentials, body-on-frame construction, luxurious interior, powerful V8 engine, exceptional off-road capability.

Value Proposition:

An officially licensed software manual provides access to the same detailed information used by authorized Mercedes-Benz technicians, ensuring accuracy and completeness for complex repairs and maintenance.

📋 Manual Details

Coverage:

Comprehensive mechanical, electrical, and bodywork diagnostics and repair procedures for the 2003 Mercedes-Benz G500.

Estimated Page Count:

1500+

Type:

Official Service and Repair Manual Software

Language:

English

Format:

Digital Software (Likely PDF or proprietary application)

📖 Manual Coverage

Engine:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management (ECU).

Transmission:

5G-TRONIC automatic transmission: removal, installation, overhaul, fluid specifications, electronic controls.

Drivetrain:

Front and rear axles, differentials, transfer case (4-ETS, lockable differentials), drive shafts, CV joints.

Suspension:

Independent front suspension, solid rear axle, springs, shock absorbers, control arms, anti-roll bars, electronic stability program (ESP) components.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, rotors, pads, brake lines, parking brake.

Steering:

Power steering system, steering column, steering gear, steering linkage.

Electrical:

Battery, charging system (alternator), starter, lighting (headlamps, taillamps, interior), power windows, power locks, mirrors, wipers, horn, fuse boxes, relays, wiring diagrams.

Climate Control:

HVAC system: A/C compressor, evaporator, condenser, blower motor, controls, refrigerant types and capacities.

Body:

Body panels, doors, hood, tailgate, glass, trim, upholstery, structural components, corrosion prevention.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), troubleshooting charts, sensor testing.

Maintenance:

Oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement, belt inspection and replacement, brake fluid flush.

Repair:

Engine component overhaul, transmission repair, suspension component replacement, brake system repairs, electrical component troubleshooting and replacement, body panel repair.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.

Diagnostics Testing:

Component testing, circuit diagnosis, pressure tests, scan tool data interpretation.

Depth:

Detailed step-by-step instructions, torque specifications, special tool requirements, diagnostic flowcharts, wiring diagrams, exploded views.

📊 Manual Specifications

Software Requirements:

Requires a compatible operating system (e.g., Windows XP or later) and potentially specific software for viewing/interaction.

Print Capability:

Printable pages for convenient workshop use. High-resolution graphics and diagrams.

Binding:

N/A (Software Format)

Paper Quality:

N/A (Software Format)

⚙️ Engine Specifications

Engine Type:

V8 SOHC (Single Overhead Camshaft)

Displacement:

4.966 liters (303 cubic inches)

Horsepower:

292 hp @ 5500 rpm

Torque:

335 lb-ft @ 3500 rpm

Fuel Delivery:

Sequential multi-port fuel injection (SFI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Coolant Capacity:

Approximately 10.5 liters (11.1 US quarts)

Oil Capacity:

Approximately 8.0 liters (8.5 US quarts)

Recommended Oil Viscosity:

SAE 0W-40 (MB 229.5 specification)

🔧 Transmission

Type:

5-speed automatic transmission (5G-TRONIC)

Options:

None for 2003 G500 model.

Gear Selection:

Standard P-R-N-D-3-2-1 selector with electronic shifting and potential for manual mode.

Transmission Fluid Type:

MB 236.10 or MB 236.12 automatic transmission fluid (ATF)

Fluid Capacity:

Approximately 7.5 liters (7.9 US quarts) for a dry fill, less for a fluid change.

📐 Dimensions

Wheelbase:

2850 mm (112.2 inches)

Length:

4630 mm (182.3 inches)

Width:

1760 mm (69.3 inches)

Height:

1931 mm (76.0 inches)

Curb Weight:

Approximately 2300 kg (5070 lbs)

Gross Vehicle Weight Rating:

Approximately 3000 kg (6614 lbs)

Cargo Volume:

Approximately 565 liters (20.0 cubic feet) with rear seats up, expandable significantly with seats folded.

🛡️ Safety Features

NHTSA Front Impact:

4-star driver, 4-star passenger (for the period).

IIHS Side Impact:

Acceptable (for the period).

Electronic Stability Program:

Standard (ESP)

Traction Control:

Standard (4-ETS - Electronic Traction System)

ABS:

Standard (Anti-lock Braking System)

Airbags:

Front dual-stage airbags, front side-impact airbags, optional rear side-impact airbags.

Seat Belts:

Three-point seat belts with pretensioners and force limiters.

💡 Technology Features

Audio System:

Standard Mercedes-Benz audio system with CD player, AM/FM radio. Optional Bose sound system.

Navigation:

Optional COMAND (Cockpit Management and Navigation) system with integrated GPS navigation.

Cruise Control:

Standard electronic cruise control.

Parking Assist:

Optional rear parking sensors.

Phone Integration:

Optional Mercedes-Benz hands-free communication system (requires specific compatible phone modules).

Headlights:

Halogen or Xenon (HID) projector headlamps, depending on trim and options. Automatic headlamp control.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 miles or 12 months, whichever comes first, or as indicated by the Flexible Service System (ASSYST).

Transmission Fluid Service:

Recommended every 50,000-60,000 miles, though often debated. Consult the manual for specific recommendations.

Spark Plug Replacement:

Approximately every 100,000 miles (iridium type plugs).

Coolant Type:

Mercedes-Benz approved coolant (e.g., G48, blue)

Brake Fluid Type:

DOT 4

Common Wear Items:

Water pump, alternator, serpentine belt, various suspension bushings, MAF sensor, O2 sensors, catalytic converters (due to age/mileage).

Electrical Quirks:

Window regulators, central locking mechanisms, interior electronics can be susceptible to failure over time.

Off Road Related:

Transfer case and differential seals, rust on body and frame components (depending on climate and usage).

📚 Vehicle History

Mercedes Benz Heritage:

Mercedes-Benz has a long history of engineering robust and luxurious vehicles, with a particular strength in off-road capability and durability dating back to early military vehicles.

G Wagen History:

The G-Wagen (Geländewagen) was originally developed as a military vehicle in the 1970s. It was introduced to the civilian market in 1979 and has maintained its distinctive, utilitarian-inspired design and exceptional off-road capabilities throughout its generations, receiving luxury and technological upgrades.

Production Location:

Graz, Austria (by Magna Steyr)

Model Variant Years:

The W463 generation of the G-Class began in 1990. The G500 variant with the M113 engine was introduced in the early 2000s, with the 2003 model year representing a significant iteration.

🏆 Awards & Recognition

Off Road Acclaim:

Consistently recognized for its class-leading off-road capability and durability in automotive publications and by off-road enthusiasts.

Luxury SUV Status:

Maintains a strong reputation as a luxurious and highly capable SUV, often considered a status symbol.