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Mercedes Benz G Wagen 460 280GE Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Model Code: W460 Variant: 280GE Generation Generation Name: First Generation (W460) Codes Chassis Code: W460 Engine Code: M110 (likely for 280GE) 👋 Introduction Market Position Segment: Rugged Off-Road Luxury SUV Target Audience: Off-road enthusiasts, collectors of classic Mercedes-Benz, owners seeking in-depth maintenance knowledge. Competitive Analysis Key Competitors Era: Land Rover Defender, Toyota Land Cruiser (early models), Jeep Wrangler Key Features Manual Value Proposition: Provides a cost-effective alternative to dealership service for a specialized, capable vehicle. Vehicle Usp: Exceptional off-road capability combined with Mercedes-Benz build quality and comfort. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Workshop Service and Repair Page Count Estimated Page Count: High (specific count not provided, but described as '100% complete and intact' with 'hundreds of photos and illustrations') Manual Type Type: Factory Service Repair Manual Language Language: English (inferred from product description) Format Format: PDF (downloadable) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Transmission (Manual/Automatic), Drivetrain (4x4 System, Differentials, Axles) Chassis: Suspension (Front/Rear), Steering, Brakes (Hydraulic, Parking), Wheels, Tires Electrical: Battery, Charging System, Starting System, Lighting System, Instrumentation, Wiring Diagrams, Fuses, Relays, Accessory Systems Body And Frame: Body Panels, Doors, Hood, Tailgate, Interior Trim, Glass, Chassis Frame, Structural Components Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication, Inspections Repair: Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Bodywork Repairs Diagnostics: Troubleshooting Guides, Symptom-Based Diagnosis, Component Testing Procedures Disassembly Assembly: Complete step-by-step instructions for disassembly and reassembly of all major vehicle components. Technical Depth Depth: Highly detailed, covering full vehicle teardown and rebuild; suitable for DIY and professional mechanics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within PDF (standard for modern service manuals) Print Quality Printability: All pages printable Binding Type Binding: Digital Download (PDF) - No physical binding Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family: M110 Inline-Six Displacement: 2.8 Liters (2746 cc) Configuration: Inline 6-cylinder, DOHC (Double Overhead Camshaft) Induction: Naturally Aspirated Bore X Stroke: 86.0 mm x 78.8 mm (estimated) Compression Ratio: 8.0:1 or 9.0:1 (depending on variant/market) Fuel Delivery: Bosch K-Jetronic Fuel Injection (likely for 280GE) Horsepower Output: Approx. 150-155 hp @ 5250-5500 rpm (estimated) Torque Output: Approx. 220-225 Nm @ 3500-4000 rpm (estimated) Performance Top Speed: Approx. 160-170 km/h (estimated) Fuel System Fuel Type: Unleaded Gasoline (Premium) Fuel Tank Capacity: Approx. 75-100 Liters (depending on configuration) 🔧 Transmission Standard Transmission Type: 4-speed Manual Transmission (likely) Optional Transmission Type: 4-speed Automatic Transmission (optional, Mercedes-Benz 4G-Tronic) Features Transfer Case: 2-speed Transfer Case with selectable 4WD and locking differentials (center, front, rear - depending on specification). Gear Ratios: Detailed ratios for manual and automatic transmissions, as well as transfer case low range, would be in the manual. 📐 Dimensions Exterior Wheelbase: 2850 mm (standard wheelbase) Length: Approx. 4200-4300 mm (depending on body style and bumpers) Width: Approx. 1760 mm Height: Approx. 1950-2000 mm (depending on tires and roof configuration) Weights Curb Weight: Approx. 1900-2100 kg (depending on configuration) Gross Vehicle Weight Rating: Approx. 2700-3000 kg (estimated) 🛡️ Safety Features Ratings Crash Test Data: Limited formal crash test data available for this era and specific vehicle, emphasis on robust construction. Active Features Braking System: Hydraulic disc brakes front, drum brakes rear (early models). ABS likely introduced later in W460 or standard on specific trims/markets. Manual will detail ABS operation if equipped. Four Wheel Drive: Full-time 4WD with lockable center differential and optional front/rear differentials. Crucial safety feature for off-road stability. Passive Features Chassis Construction: Body-on-frame construction for inherent durability and off-road resilience. Seat Belts: Standard front seat belts, rear seat belts depending on configuration/market. 💡 Technology Features Infotainment Audio System: Basic factory radio with AM/FM, potentially cassette player. Manual will cover basic operation and fuse locations. Driver Assistance Traction Control: Limited or no electronic driver assistance systems like traction control or stability control. Emphasis is on mechanical off-road capability. Connectivity Auxiliary Inputs: N/A for this era of vehicle. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000 - 7,500 miles or 6-12 months (refer to manual for specific intervals based on usage and oil type). Major Service Intervals: Detailed in manual (e.g., spark plug replacement, transmission fluid service, coolant flush). Fluid Specifications Engine Oil Type: Refer to manual, likely SAE 10W-40 or 15W-40 API SG/SH rated oil for this era, or specific synthetic grades. Engine Oil Capacity: Approx. 6.0 - 6.5 Liters (including filter). Transmission Fluid Type Manual: GL-4 or GL-5 gear oil (specific viscosity recommended in manual, e.g., 75W-90). Transmission Fluid Type Automatic: Mercedes-Benz Approved Automatic Transmission Fluid (e.g., Dexron II/III compatible variants, consult manual). Coolant Type: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Refer to manual for specific Mercedes-Benz coolant specification (e.g., G48). Brake Fluid Type: DOT...
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Mercedes Benz G Wagen 460 280GE Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
G-Wagen
Model Code:
W460
Variant:
280GE
Generation
Generation Name:
First Generation (W460)
Codes
Chassis Code:
W460
Engine Code:
M110 (likely for 280GE)
👋 Introduction
Market Position
Segment:
Rugged Off-Road Luxury SUV
Target Audience:
Off-road enthusiasts, collectors of classic Mercedes-Benz, owners seeking in-depth maintenance knowledge.
Competitive Analysis
Key Competitors Era:
Land Rover Defender, Toyota Land Cruiser (early models), Jeep Wrangler
Key Features
Manual Value Proposition:
Provides a cost-effective alternative to dealership service for a specialized, capable vehicle.
Vehicle Usp:
Exceptional off-road capability combined with Mercedes-Benz build quality and comfort.
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Workshop Service and Repair
Page Count
Estimated Page Count:
High (specific count not provided, but described as '100% complete and intact' with 'hundreds of photos and illustrations')
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (inferred from product description)
Format
Format:
PDF (downloadable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission (Manual/Automatic), Drivetrain (4x4 System, Differentials, Axles)
Chassis:
Suspension (Front/Rear), Steering, Brakes (Hydraulic, Parking), Wheels, Tires
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Wiring Diagrams, Fuses, Relays, Accessory Systems
Body And Frame:
Body Panels, Doors, Hood, Tailgate, Interior Trim, Glass, Chassis Frame, Structural Components
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication, Inspections
Repair:
Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Bodywork Repairs
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnosis, Component Testing Procedures
Disassembly Assembly:
Complete step-by-step instructions for disassembly and reassembly of all major vehicle components.
Technical Depth
Depth:
Highly detailed, covering full vehicle teardown and rebuild; suitable for DIY and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text within PDF (standard for modern service manuals)
Print Quality
Printability:
All pages printable
Binding Type
Binding:
Digital Download (PDF) - No physical binding
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M110 Inline-Six
Displacement:
2.8 Liters (2746 cc)
Configuration:
Inline 6-cylinder, DOHC (Double Overhead Camshaft)
Induction:
Naturally Aspirated
Bore X Stroke:
86.0 mm x 78.8 mm (estimated)
Compression Ratio:
8.0:1 or 9.0:1 (depending on variant/market)
Fuel Delivery:
Bosch K-Jetronic Fuel Injection (likely for 280GE)
Horsepower Output:
Approx. 150-155 hp @ 5250-5500 rpm (estimated)
Torque Output:
Approx. 220-225 Nm @ 3500-4000 rpm (estimated)
Performance
Top Speed:
Approx. 160-170 km/h (estimated)
Fuel System
Fuel Type:
Unleaded Gasoline (Premium)
Fuel Tank Capacity:
Approx. 75-100 Liters (depending on configuration)
🔧 Transmission
Standard
Transmission Type:
4-speed Manual Transmission (likely)
Optional
Transmission Type:
4-speed Automatic Transmission (optional, Mercedes-Benz 4G-Tronic)
Features
Transfer Case:
2-speed Transfer Case with selectable 4WD and locking differentials (center, front, rear - depending on specification).
Gear Ratios:
Detailed ratios for manual and automatic transmissions, as well as transfer case low range, would be in the manual.
📐 Dimensions
Exterior
Wheelbase:
2850 mm (standard wheelbase)
Length:
Approx. 4200-4300 mm (depending on body style and bumpers)
Width:
Approx. 1760 mm
Height:
Approx. 1950-2000 mm (depending on tires and roof configuration)
Weights
Curb Weight:
Approx. 1900-2100 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 2700-3000 kg (estimated)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited formal crash test data available for this era and specific vehicle, emphasis on robust construction.
Active Features
Braking System:
Hydraulic disc brakes front, drum brakes rear (early models). ABS likely introduced later in W460 or standard on specific trims/markets. Manual will detail ABS operation if equipped.
Four Wheel Drive:
Full-time 4WD with lockable center differential and optional front/rear differentials. Crucial safety feature for off-road stability.
Passive Features
Chassis Construction:
Body-on-frame construction for inherent durability and off-road resilience.
Seat Belts:
Standard front seat belts, rear seat belts depending on configuration/market.
💡 Technology Features
Infotainment
Audio System:
Basic factory radio with AM/FM, potentially cassette player. Manual will cover basic operation and fuse locations.
Driver Assistance
Traction Control:
Limited or no electronic driver assistance systems like traction control or stability control. Emphasis is on mechanical off-road capability.
Connectivity
Auxiliary Inputs:
N/A for this era of vehicle.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 7,500 miles or 6-12 months (refer to manual for specific intervals based on usage and oil type).
Major Service Intervals:
Detailed in manual (e.g., spark plug replacement, transmission fluid service, coolant flush).
Fluid Specifications
Engine Oil Type:
Refer to manual, likely SAE 10W-40 or 15W-40 API SG/SH rated oil for this era, or specific synthetic grades.
Engine Oil Capacity:
Approx. 6.0 - 6.5 Liters (including filter).
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil (specific viscosity recommended in manual, e.g., 75W-90).
Transmission Fluid Type Automatic:
Mercedes-Benz Approved Automatic Transmission Fluid (e.g., Dexron II/III compatible variants, consult manual).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Refer to manual for specific Mercedes-Benz coolant specification (e.g., G48).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (confirm in manual).
Known Issues
Common Wear Items:
Fuel pumps, exhaust systems, suspension bushings, brake components, ignition system components (spark plugs, wires), starter motors, clutch components (manual).
Rust Prone Areas:
Fender wells, rocker panels, tailgate hinges, frame outriggers, battery tray area. Regular inspection and undercoating are crucial.
Fuel System Maintenance:
Regular fuel filter replacement and potential need for injector servicing with K-Jetronic systems.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Mercedes-Benz's reputation for engineering excellence, durability, and off-road prowess established through military contracts and civilian models.
Model Evolution
W460 Introduction:
Introduced in 1979, developed in conjunction with military requirements for a robust all-terrain vehicle.
280Ge Positioning:
The 280GE was one of the gasoline-powered variants, offering a balance of performance and refinement for civilian use.
Production
Production Period W460:
1979 - 1993
Manufacturing Location:
Graz, Austria (Magna Steyr)
🏆 Awards & Recognition
Recognitions
Military Designation:
Many W460 variants served with military forces worldwide, a testament to their robustness and capability.
Ratings
Off Road Capability Rating:
Universally recognized as one of the most capable factory off-road vehicles ever produced.
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