🏷️ Basic Information

Make:

Mercedes-Benz

Model:

G-Class

Chassis Code:

W463

Model Year:

2002

Generation Code:

W463

👋 Introduction

Target Audience:

Mercedes-Benz G-Class owners and independent repair technicians

Value Proposition:

Provides dealership-level diagnostic and repair information at a fraction of the cost, empowering owners to perform their own maintenance and repairs.

Authenticity:

Exact same manual used by dealership technicians

Comprehensiveness:

Covers all models and all repairs A-Z

Usability:

One easy-to-use PDF, printable pages, digital format for cleanliness and durability

Vehicle Type:

Luxury, off-road focused SUV

Accuracy:

Explicitly states 'NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC.'

📋 Manual Details

Primary Coverage:

All Models and All Repairs A-Z

Geographic Scope:

Global (based on factory specifications)

Estimated Pages:

Extensive (specific count not provided, but described as comprehensive for all repairs)

Type:

Factory Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

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:

Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering

Body And Interior:

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

Electrical And Electronics:

Electrical, Multiplex/ Can Communication

Maintenance:

Complete step-by-step instructions for routine maintenance

Diagnostics:

Troubleshooting and diagnostic procedures for all systems

Repair:

Detailed repair procedures for all components and systems

Technical Data:

Specifications, wiring schematics, diagrams, and illustrations

Depth:

Factory-level detail for technicians, covering all repairs A-Z

📊 Manual Specifications

Compatibility:

Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac compatible

Requirements:

Adobe PDF Reader, Winzip (free online)

Printability:

All pages are printable, allowing for enlarged image printing

Binding:

Digital (PDF) - no physical binding

Paper Type:

N/A (Digital Format)

Searchability:

Implied (typical PDF functionality), allows for printing specific pages

Navigation:

Easy-to-use, single PDF manual, eliminating flipping through books

⚙️ Engine Specifications

Engine Type:

Varies by specific G-Class W463 model for 2002. Likely candidates include the M112 (4.3L V8) and M113 (5.0L V8) gasoline engines, or OM606 (3.0L turbodiesel) or OM612 (2.7L turbodiesel) diesel engines. Specific engine code not provided in product description.

Horsepower Torque:

Varies significantly by engine option. For example, the G500 (M113) produced around 292 hp and 387 lb-ft of torque. Specific figures require identifying the exact engine.

Fuel Delivery:

Likely Multi-Point Fuel Injection (MPI) or Direct Injection for gasoline engines, Common Rail Diesel Injection (CDI) for diesel engines.

Cooling Type:

Pressurized liquid cooling system

Oil Type:

Refer to manual for specific OEM specifications (e.g., MB 229.1, MB 229.3, or MB 229.5 for gasoline).

🔧 Transmission

Transmission Type:

Likely a 5-speed automatic transmission (e.g., 722.6 '7G-TRONIC' or earlier versions) or a 6-speed manual transmission depending on the specific model variant.

Optional Transmission:

Dependent on market and trim. Manual transmission option may be available on some variants.

Drivetrain:

Full-time 4MATIC all-wheel drive with locking differentials

Transmission Fluid:

Refer to manual for specific OEM specifications (e.g., ATF specifications like MB 236.10 or similar for automatic transmissions).

📐 Dimensions

Wheelbase:

Approximately 2850 mm (112.2 in) for standard wheelbase.

Length:

Approximately 4605 mm (181.3 in) for standard wheelbase.

Width:

Approximately 1760 mm (69.3 in).

Height:

Approximately 1931 mm (76.0 in).

Curb Weight:

Varies by engine and equipment, typically between 2100 kg (4630 lbs) to 2300 kg (5070 lbs).

Towing Capacity:

Refer to manual for specific ratings, generally high for G-Class variants.

Wheel Size:

Commonly 16-inch or 18-inch alloy wheels.

Tire Size:

Examples: 265/70 R16, 255/55 R18. Specific sizes depend on trim and options. Manual will detail correct fitments.

🛡️ Safety Features

Crash Test Results:

While specific 2002 NHTSA/IIHS ratings might be scarce for this era and model, the W463 is known for its robust body-on-frame construction and off-road capability, offering inherent structural integrity. Manual will cover safety systems.

Traction Control:

Standard ASR (Acceleration Slip Regulation) and ESP (Electronic Stability Program) depending on specific model year and configuration.

Brake System:

Anti-lock Braking System (ABS) on all wheels, often with Electronic Brake-force Distribution (EBD).

Airbags:

Front airbags for driver and passenger, potentially side airbags depending on trim.

Seat Belts:

Three-point seat belts with pre-tensioners for front occupants.

Immobilizer:

Factory-installed engine immobilizer (often part of the 'CODE' immobilizer system).

💡 Technology Features

Audio System:

Factory-installed audio system with AM/FM radio, CD player, and premium sound options (e.g., Bose) available depending on trim.

Navigation:

Optional GPS navigation system (COMAND system) may have been available on higher trims.

Cruise Control:

Standard or optional cruise control system.

Multiplex Communication:

Inclusion of CAN (Controller Area Network) bus systems for various electronic module communication, as indicated by 'Multiplex/ Can Communication' in coverage.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 miles (15,000-25,000 km) or 12 months, depending on driving conditions and specific engine oil used. Manual will provide exact intervals.

Major Service:

Intervals for spark plugs, coolant flush, transmission service, differential fluid changes, etc., are detailed in the manual, often around 30,000-60,000 miles.

Engine Oil Specification:

Refer to manual for specific MB-Approval specifications (e.g., MB 229.1, MB 229.3, MB 229.5). Viscosity grades such as 0W-40 or 5W-40 are common.

Coolant Type:

Mercedes-Benz approved coolant (typically a silicate-free organic acid technology - OAT) mixed with distilled water. Specific MB-Approval required.

Brake Fluid Type:

DOT 4 or DOT 5.1 brake fluid, conforming to Mercedes-Benz specifications.

Common Problems:

Potential issues can include minor oil leaks from engine seals or gaskets, aging of rubber components in the suspension and cooling system, and electronics issues related to age. The manual will guide diagnosis and repair.

Specific Component Wear:

Brake wear, suspension component wear (bushings, ball joints), and potential for fuel pump or ignition coil failures as the vehicle ages.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long history of producing robust, high-quality vehicles, with a particular reputation for durable off-road vehicles and luxury SUVs.

G Class Development:

The G-Class (W463) was introduced in 1989 as a luxury evolution of the original G-Wagen, designed for both off-road prowess and on-road comfort, retaining its characteristic body-on-frame construction and three locking differentials.

Production Period W463:

The W463 platform was in production from 1989 until 2018, with significant updates throughout its lifecycle.

Manufacturing Plant:

Graz, Austria (by Magna Steyr)

🏆 Awards & Recognition

Off Road Acclaim:

The G-Class is widely recognized for its exceptional off-road capabilities and durability, often earning accolades in off-road enthusiast circles and by its ability to tackle challenging terrains.

Overall Durability:

The G-Class is consistently lauded for its build quality and long-term durability, often considered a 'classic' vehicle due to its enduring design and robust construction.

Factory Certification:

This manual is a factory-certified document, meaning it meets the rigorous standards set by Mercedes-Benz for technical documentation.