Mercedes Benz G wagen 460 280GE Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Specific Model Variant: 280GE Model Years Covered: Typically covers early to mid-production W460 models, including those with the 280GE engine. Specific years would need to be confirmed by the manual's content, but generally 1979-1991. Codes Engine Code: M110 (for 280GE) 👋 Introduction Market Position Vehicle Segment: Luxury SUV, off-road utility vehicle. Target Audience: Enthusiasts, owners seeking to perform their own maintenance and repairs on a classic Mercedes-Benz G-Wagen. Competitive Analysis Competitors Era: Land Rover Defender, Toyota Land Cruiser, Jeep Wagoneer (during its production era). Key Features Vehicle Philosophy: Uncompromising off-road capability combined with Mercedes-Benz build quality and luxury. Manual Value Proposition: Provides detailed, authoritative technical guidance essential for maintaining and repairing the robust W460 G-Wagen. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English (assumed, standard for most widely distributed manuals) Format: PDF Page Count Estimated Page Count: Likely 500-1000+ pages, typical for comprehensive factory-level service manuals. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, crankshaft, pistons, connecting rods, camshafts, valve train, timing. Engine Fuel System: Fuel injection system (Bosch K-Jetronic or similar for 280GE), fuel pump, injectors, pressure regulator, fuel lines. Engine Ignition System: Distributor, ignition coils, spark plugs, timing adjustment. Engine Cooling System: Radiator, water pump, thermostat, hoses, fan. Engine Lubrication System: Oil pump, oil filter, oil pan, lubrication passages. Transmission Manual: Disassembly, assembly, adjustment, shift mechanism, clutch, flywheel. Transmission Automatic: If applicable to specific 280GE variants, torque converter, valve body, planetary gears, fluid and filter service. Drivetrain Front Axle: Differential, axle shafts, CV joints, steering knuckles. Drivetrain Rear Axle: Differential, axle shafts, housing. Drivetrain Transfer Case: Operation, maintenance, repair, lubrication. Suspension Front: Coil springs, shock absorbers, control arms, bushings, sway bar. Suspension Rear: Leaf springs or coil springs (depending on variant), shock absorbers, trailing arms, Panhard rod, bushings. Steering System: Power steering pump, steering gearbox, steering column, tie rods, linkages. Brake System: Front disc brakes, rear drum brakes (or discs depending on variant), master cylinder, brake booster, proportioning valve, ABS (if equipped), lines, bleeding procedures. Electrical System Battery: Battery, charging system (alternator, voltage regulator). Electrical System Lighting: Headlights, taillights, interior lights, wiring diagrams. Electrical System Instruments: Dashboard gauges, warning lights, switchgear. Electrical System Accessories: Wipers, horn, power windows (if equipped), radio, HVAC blower motor. Body Interior: Seat removal, dashboard components, door panels, headliner, carpet. Body Exterior: Doors, hood, tailgate, fenders, bumpers, glass replacement, trim. Body Chassis: Frame inspection, rust repair, welding procedures. HVAC System: Heater core, evaporator, blower motor, refrigerant system (if A/C equipped), controls. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, lubrication points. Troubleshooting: Diagnostic charts for common symptoms, electrical fault finding with wiring diagrams. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation. Diagnostics: Engine performance diagnostics, electrical system testing. Wiring Diagrams: Comprehensive electrical schematics for various systems. Torque Specifications: Detailed torque values for critical fasteners. Special Tools: Identification of necessary special tools for specific procedures. Technical Depth Depth Level: Factory-level, comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text within the PDF, allowing for quick information retrieval. Printable: High-quality PDF format, designed for easy printing of specific sections or the entire manual. Print Quality Image Resolution: High resolution for clear diagrams, illustrations, and schematics. Binding Type Format Type: Digital (PDF) Paper Type Format Type: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Name: M110 Inline-6 Engine Type: Naturally Aspirated, Overhead Camshaft (OHC), Dual Carburetor or Fuel Injection (depending on specific 280GE variant). Displacement: 2.8 Liters (2746 cc) Performance Horsepower: Approximately 150-160 hp (varies slightly by specific model year and configuration). Torque: Approximately 170-180 lb-ft (varies slightly). Fuel System Fuel Delivery: Bosch K-Jetronic (CIS) Fuel Injection on later 280GE models. Earlier models might have dual Solex carburetors. Manual should cover the specific system. Fuel Type: Unleaded Gasoline (Octane rating as per manufacturer specification, typically 91 or higher). Engine Management Engine Control Unit: If fuel injected, an electronic control unit (ECU) manages ignition and fuel delivery. 🔧 Transmission Standard Transmission Type Standard: 4-speed Manual Transmission (e.g., G460-XXXX model codes). Optional Transmission Type Optional: 4-speed Automatic Transmission (e.g., 722.3xx series). Features Gear Ratios: Specific gear ratios for both manual and automatic transmissions will be detailed in the manual. Transfer Case: Two-speed transfer case with selectable 4WD and locking differentials (center, rear, and sometimes front) are key features of the W460. Fluid Specifications Manual Transmission Fluid: GL-4 or GL-5 gear oil, viscosity as per Mercedes-Benz specifications (e.g., SAE 75W-90). Automatic Transmission Fluid: Dexron II or equivalent specification fluid (e.g., MB 236.3). 📐 Dimensions Exterior Wheelbase: Short wheelbase (SWB): approx. 2400 mm; Long wheelbase (LWB): approx. 2850 mm. (Manual will confirm specific variants). Length: Varies...
Typically covers early to mid-production W460 models, including those with the 280GE engine. Specific years would need to be confirmed by the manual's content, but generally 1979-1991.
Codes
Engine Code:
M110 (for 280GE)
👋 Introduction
Market Position
Vehicle Segment:
Luxury SUV, off-road utility vehicle.
Target Audience:
Enthusiasts, owners seeking to perform their own maintenance and repairs on a classic Mercedes-Benz G-Wagen.
Competitive Analysis
Competitors Era:
Land Rover Defender, Toyota Land Cruiser, Jeep Wagoneer (during its production era).
Key Features
Vehicle Philosophy:
Uncompromising off-road capability combined with Mercedes-Benz build quality and luxury.
Manual Value Proposition:
Provides detailed, authoritative technical guidance essential for maintaining and repairing the robust W460 G-Wagen.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English (assumed, standard for most widely distributed manuals)
Format:
PDF
Page Count
Estimated Page Count:
Likely 500-1000+ pages, typical for comprehensive factory-level service manuals.
Diagnostic charts for common symptoms, electrical fault finding with wiring diagrams.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Diagnostics:
Engine performance diagnostics, electrical system testing.
Wiring Diagrams:
Comprehensive electrical schematics for various systems.
Torque Specifications:
Detailed torque values for critical fasteners.
Special Tools:
Identification of necessary special tools for specific procedures.
Technical Depth
Depth Level:
Factory-level, comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text within the PDF, allowing for quick information retrieval.
Printable:
High-quality PDF format, designed for easy printing of specific sections or the entire manual.
Print Quality
Image Resolution:
High resolution for clear diagrams, illustrations, and schematics.
Binding Type
Format Type:
Digital (PDF)
Paper Type
Format Type:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
M110 Inline-6
Engine Type:
Naturally Aspirated, Overhead Camshaft (OHC), Dual Carburetor or Fuel Injection (depending on specific 280GE variant).
Displacement:
2.8 Liters (2746 cc)
Performance
Horsepower:
Approximately 150-160 hp (varies slightly by specific model year and configuration).
Torque:
Approximately 170-180 lb-ft (varies slightly).
Fuel System
Fuel Delivery:
Bosch K-Jetronic (CIS) Fuel Injection on later 280GE models. Earlier models might have dual Solex carburetors. Manual should cover the specific system.
Fuel Type:
Unleaded Gasoline (Octane rating as per manufacturer specification, typically 91 or higher).
Engine Management
Engine Control Unit:
If fuel injected, an electronic control unit (ECU) manages ignition and fuel delivery.
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Manual Transmission (e.g., G460-XXXX model codes).
Specific gear ratios for both manual and automatic transmissions will be detailed in the manual.
Transfer Case:
Two-speed transfer case with selectable 4WD and locking differentials (center, rear, and sometimes front) are key features of the W460.
Fluid Specifications
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, viscosity as per Mercedes-Benz specifications (e.g., SAE 75W-90).
Automatic Transmission Fluid:
Dexron II or equivalent specification fluid (e.g., MB 236.3).
📐 Dimensions
Exterior
Wheelbase:
Short wheelbase (SWB): approx. 2400 mm; Long wheelbase (LWB): approx. 2850 mm. (Manual will confirm specific variants).
Length:
Varies significantly by body style (e.g., 2-door, 4-door, Wolf).
Weights
Curb Weight:
Approximately 1900-2200 kg, depending on configuration.
Gross Vehicle Weight Rating:
Typically around 2800-3000 kg.
🛡️ Safety Features
Ratings
Crash Test Data:
While formal modern crash test data for early W460 models might be limited, the robust ladder frame construction and inherent weight provide a degree of passive safety. The manual may reference internal safety testing or structural integrity data.
Active Features
Braking System:
Front disc brakes, rear drum brakes are standard. ABS was optional on later models. Manual will detail operation and diagnostics.
Passive Features
Frame Construction:
Heavy-duty ladder frame chassis, contributing to rigidity and occupant protection in off-road and moderate impact scenarios.
Seat Belts:
Three-point seat belts typically standard in the front, with lap belts or three-point belts in the rear depending on seating configuration.
💡 Technology Features
Infotainment
Audio System:
Basic analog radio/cassette players were common. The manual will cover the basic wiring and installation/removal of the head unit and speakers.
Driver Assistance
ABS:
Anti-lock Braking System was optional on later W460 models. The manual will cover its operation, diagnostics, and repair.
Connectivity
Wiring Harnesses:
Detailed wiring diagrams are a critical technology feature covered by the manual for troubleshooting electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions. Manual will provide specific recommendations.
Filter Replacement Interval:
Oil filter with every oil change. Air filter and fuel filter typically every 20,000-40,000 km. Manual will specify.
Spark Plug Replacement:
Varies by plug type, generally 30,000-60,000 km. Manual will detail.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-40 or 15W-40 common. Specific viscosity recommended by MB.
Coolant Type:
Ethylene glycol-based coolant, typically MB 325.0 specification (green or blue).
Potential for oil leaks from the M110 engine, ignition system component failures, fuel distributor issues on K-Jetronic systems. Manual provides diagnostic steps.
📚 Vehicle History
Brand Heritage
Mercedes Benz Heritage:
Mercedes-Benz has a long history of producing robust, high-quality vehicles, including military and utility vehicles, which laid the groundwork for the G-Wagen's development.
Model Evolution
W460 Development:
Developed in the 1970s for military and civilian use, emphasizing ruggedness, durability, and exceptional off-road capability. The 280GE was one of the early civilian variants.
Production
Production Period W460:
1979-1991
Manufacturing Location:
Graz, Austria (by Magna Steyr, under contract for Mercedes-Benz).
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
The G-Wagen, in its various forms, has consistently been recognized for its exceptional off-road prowess, often winning or performing exceptionally in international off-road challenges and military evaluations.
Longevity Awards:
The W460's design has proven remarkably enduring, with the G-Wagen platform continuing production for over four decades, a testament to its fundamental engineering. While specific awards for the early W460 might be scarce, its reputation for durability is its primary recognition.
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