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2010 Mercedes G-Class (W463) Service and Repair Manual

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Basic Information Identification Make: Mercedes-Benz Model: G-Class Model Code: W463 Year: 2010 Generation Generation Code: W463 (Second Generation) Codes Chassis Code: W463 Introduction Market Position Segment: Luxury SUV, Off-Road Vehicle...
Type: Cars
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2010 Mercedes G-Class (W463) Service and Repair Manual
Basic Information
Identification
Make: Mercedes-Benz
Model: G-Class
Model Code: W463
Year: 2010
Generation
Generation Code: W463 (Second Generation)
Codes
Chassis Code: W463
Introduction
Market Position
Segment: Luxury SUV, Off-Road Vehicle
Target Audience: Discerning buyers valuing off-road capability, luxury, and robust engineering; owners seeking to maintain and repair their vehicle themselves or with greater understanding.
Competitive Analysis
Competitors 2010: Land Rover Range Rover, Toyota Land Cruiser, Lexus LX, Cadillac Escalade, Lincoln Navigator
Key Features
G Class Attributes: Exceptional off-road prowess (locking differentials, robust chassis), distinctive boxy styling, luxury interior appointments, legendary durability and build quality.
Manual Value Proposition
Benefit To Owner: Empowers owners to perform diagnostics, maintenance, and repairs with factory-accurate information, saving time and money compared to dealership service; fosters deeper understanding of the vehicle's complex systems.
Manual Details
Coverage Areas
All Models Covered: Yes
Repair Scope: All Repairs A-Z
Page Count
Estimated Page Count: Detailed Technician-Level Manual (Exact page count varies by specific model variant and engine, typically several thousand pages for comprehensive factory manuals)
Manual Type
Type: Factory Service and Repair Manual
Language
Language: English
Format
Format: PDF
Accessibility: Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac Compatible
Manual Coverage
Systems Covered
Engine Management: Engine diagnostics, control systems, fuel service specifications, emission control systems, intake/exhaust, cooling systems, lubrication
Drivetrain: Mechanical components, automatic transmission, manual transmission, transfer case, propeller shaft, drive shaft, differentials, axles
Suspension Steering Brakes: Axle and suspension systems, tire and wheel specifications, brake control systems, brake systems (front/rear), parking brake
Electrical Body: Ignition, starting, charging systems, steering column, power steering, air conditioning, supplementary restraint system (SRS), seat belts, engine immobilizer, cruise control, wipers and washers, door locks, meters, audio/visual systems, horn, windshield/glass/mirrors, instrument panel, seats, engine hood/doors, exterior and interior components, electrical system, multiplex/CAN communication
Procedures Included
Diagnostic Procedures: Troubleshooting guides, fault code interpretation, diagnostic procedures for all covered systems
Maintenance Procedures: Routine maintenance tasks, fluid changes, filter replacements, inspection procedures
Repair Procedures: Complete step-by-step repair instructions for all vehicle components, including disassembly, reassembly, and adjustments
Technical Data Provision: Torque specifications, clearances, adjustment data, wiring schematics, component diagrams, illustrations
Technical Depth
Depth: Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complex diagnostics and component overhauls.
Manual Specifications
File Format
File Type: PDF
Searchability: Likely searchable text within the PDF for quick information retrieval.
Print Quality
Printability: All pages are printable, allowing users to print specific sections or diagrams as needed.
Zoom Capabilities: Images and diagrams can be blown up for enlarged viewing and printing.
Binding Type
Binding: Digital (PDF), eliminating physical binding issues.
Paper Type
Paper Usage: User-defined based on printed pages, eliminating the need for greasy or torn paper manuals.
Engine Specifications
Primary Engine
Engine Options 2010: Typically included G 550 (4.0L V8), G 500 (5.0L V8), G 350 CDI (3.0L V6 turbodiesel), and G 63 AMG (5.5L V8 Bi-Turbo or 6.2L V8 Bi-Turbo for G 65 AMG variants).
Engine Displacement Typical: Ranges from 3.0L to 6.3L depending on the specific model variant (e.g., G 350 CDI, G 500, G 55 AMG).
Engine Type Typical: V8, naturally aspirated or supercharged/turbocharged; V6 turbodiesel.
Performance
Horsepower Range Typical: Approximately 215 hp (G 350 CDI) to 500 hp+ (G 55 AMG/G 63 AMG).
Torque Range Typical: Significantly high torque figures, especially in diesel and AMG variants, crucial for off-road capability and towing.
Fuel System
Fuel Delivery: Electronic Fuel Injection (EFI), often with advanced common rail direct injection for diesel variants.
Transmission
Standard
Transmission Type Standard: Typically a 5-speed or 7-speed automatic transmission (e.g., 5G-TRONIC, 7G-TRONIC).
Optional
Transmission Type Optional: While manual transmissions were historically available in earlier G-Wagen generations, the 2010 W463 predominantly featured automatic transmissions.
Features
Transfer Case: Permanent all-wheel drive with a 2-speed transfer case featuring low-range gearing for extreme off-road conditions.
Differential Locks: Center, rear, and sometimes front differential locks, operated electronically or hydraulically, a signature feature for off-road capability.
Dimensions
Exterior
Body Styles: Typically offered in 3-door and 5-door wagon configurations. Also, cabriolet and panel van variants existed in earlier production runs, though less common for 2010.
Wheelbase Typical: Approx. 2850 mm (112.2 inches) for the standard 5-door model.
Weights
Curb Weight Typical: Varies significantly by engine and trim, generally starting around 2,100 kg (4,630 lbs) and going upwards.
Safety Features
Ratings
Crash Test Results: While specific official ratings for the 2010 W463 might vary by region, the G-Class is known for its robust body structure. Historically, it has performed well in tests due to its solid construction, but modern structural requirements can differ.
Active Features
Stability Control: Electronic Stability Program (ESP)
Traction Control: All-Wheel Drive, Traction Control System (TCS), often integrated with ESP.
Passive Features
Airbags: Front airbags, side airbags, and potentially curtain airbags depending on the specific configuration.
Seat Belts: Pretensioning seatbelts with force limiters.
Technology Features
Infotainment
Infotainment System: COMAND APS (Cockpit Management and Navigation system) with integrated radio, CD/DVD player, navigation, and auxiliary inputs. Bluetooth connectivity likely standard.
Driver Assistance
Parking Assistance: Rear parking sensors, possibly front parking sensors on higher trims. Backup camera was becoming more common.
Connectivity
Connectivity Features: Bluetooth hands-free calling and audio streaming, possibly USB integration for media playback depending on option packages.
Maintenance
Service Intervals
Oil Change Interval: Typically every 10,000-15,000 miles (16,000-24,000 km) or 12 months, whichever comes first, depending on driving conditions.
Major Service Interval: Significant services often scheduled around 30,000, 60,000, and 100,000 miles, covering transmission fluid, differential fluid, brake fluid, coolant, and spark plugs.
Fluid Specifications
Engine Oil Spec: Refer to MB 229.3 or MB 229.5 approved synthetic oils, viscosity typically 0W-40 or 5W-40 depending on climate.
Transmission Fluid Spec: MB 236.10 or MB 236.12 approved ATF for automatic transmissions.
Coolant Spec: Mercedes-Benz approved coolant (e.g., G48 or similar blue/green silicate-containing coolant).
Known Issues
Common Wear Items: Brake pads and rotors, suspension bushings, exhaust system components, power steering hoses, potential for rust on older examples, transfer case actuator issues.
Electrical Quirks: Minor electrical gremlins can occur, often related to aged wiring or module failures, but generally robust.
Vehicle History
Brand Heritage
Mercedes Benz Legacy: Mercedes-Benz has a long history of producing robust, high-quality vehicles, with the G-Class representing its pinnacle in off-road capability and ruggedness, initially developed for military purposes.
Model Evolution
W463 Development: The W463 generation, introduced in 1990, marked a significant evolution from its utilitarian predecessor (W460/W461) by incorporating more luxury, comfort, and advanced features, while retaining its core off-road DNA. The 2010 model represents a mature iteration of this platform.
Production
Manufacturing Location: Graz, Austria (by Magna Steyr)
Production Years W463: 1990 - Present (with continuous updates and facelifts)
Awards & Recognition
Recognitions
Off Road Accolades: Consistently recognized for its unparalleled off-road capability and robustness across automotive publications and enthusiast communities. Often cited as a benchmark for extreme off-road performance.
Luxury Status: Maintains a high status as a luxury SUV due to its premium materials, comfort features, and brand prestige.
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