Mercedes Benz G wagen 463 Workshop Repair Service Manual

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Basic Information Identification Make: Mercedes-Benz Model: G-Class Chassis Code: W463 Product Name: Mercedes Benz G wagen 463 Workshop Repair Service Manual PDF Introduction Market Position Positioning: The Mercedes-Benz G-Class (W463)...

Taper: Cars

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UGS: 422629

Mots clés: Mercedes Misc

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Description

Basic Information
Identification
Make:	Mercedes-Benz
Model:	G-Class
Chassis Code:	W463
Product Name:	Mercedes Benz G wagen 463 Workshop Repair Service Manual PDF

Introduction
Market Position
Positioning:	The Mercedes-Benz G-Class (W463) is positioned as a premium, highly capable off-road luxury SUV with a rich heritage, combining ruggedness with high-end amenities.
Competitive Analysis
Key Competitors:	Land Rover Defender, Toyota Land Cruiser, Jeep Wrangler Rubicon (in terms of off-road capability and ruggedness), though often competing with luxury SUVs on comfort and features.
Key Features
Distinguishing Features:	Iconic boxy styling, robust ladder frame chassis (though W463 introduced independent front suspension), standard three locking differentials, exceptional off-road prowess, luxury interior, powerful engine options.
Target Demographic
Demographic:	Affluent individuals and families seeking an extremely capable and luxurious off-road vehicle, often with a desire for adventure and status.

Manual Details
Coverage Areas
Primary Coverage:	Mechanical and electrical repair, maintenance, and diagnostics
Intended Audience:	Professional mechanical technicians
Page Count
Estimated Pages:	Extensive (specific number not provided, typical for workshop manuals covering multiple model years and variants)
Manual Type
Type:	Workshop Repair Service Manual
Language
Language:	English (presumed, based on typical market for such manuals)
Format
Format:	PDF

Manual Coverage
Systems Covered
Powertrain:	Engine (all variants), transmission (automatic and manual), differentials, transfer case, exhaust system
Chassis:	Suspension (front and rear), steering system, braking system (including ABS/ESP), wheels and tires
Electrical:	Engine control unit (ECU), body control module (BCM), lighting systems, infotainment, instrument cluster, comfort systems (HVAC, seats), power accessories
Body And Frame:	Body panels, doors, windows, sunroof, interior trim, chassis structure, corrosion protection
Procedures Included
Maintenance:	Scheduled maintenance, fluid changes, filter replacements, lubrication
Repair:	Component replacement, system diagnostics, troubleshooting, alignment, calibration
Diagnostics:	Fault code interpretation, diagnostic trouble codes (DTCs), wiring diagrams, test procedures
Special Tools:	Required special tools and equipment for specific repairs
Technical Depth
Depth:	Comprehensive, covering everything from basic fluid checks to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures

Manual Specifications
File Format
File Type:	PDF (Portable Document Format)
Searchability:	Likely text-searchable, enabling quick access to specific information
Print Quality
Print Readability:	Designed for clear printing and on-screen readability, with diagrams and illustrations
Binding Type
Binding:	N/A (Digital PDF format)
Paper Type
Paper Type:	N/A (Digital PDF format)

Engine Specifications
Primary Engine
Engine Options W463:	Varies by model year and market. Common engines include: M112 (4.3L V8), M113 (5.0L V8, 5.4L V8 AMG), M273 (5.5L V8), M156 (6.2L V8 AMG), M272 (3.5L V6), OM642 (3.0L V6 Diesel), OM629 (4.0L V8 Diesel).
Performance
Horsepower Range:	Approximately 215 hp (G320 CDI) to over 500 hp (G55 AMG, G63 AMG).
Torque Range:	Approximately 430 Nm (G320 CDI) to over 700 Nm (AMG variants).
Fuel System
Fuel Delivery:	Electronic Fuel Injection (EFI) / Direct Injection for later models.
Fuel Type:	Unleaded Gasoline (Petrol), Diesel
Engine Management
ECU Type:	Bosch Motronic, Siemens, or Continental ECUs (specific to engine variant and year).
Cooling System
Coolant Type:	Mercedes-Benz specification coolant (e.g., G48 or equivalent blue/green coolant).
Lubrication
Oil Viscosity Recommendations:	Varies by engine, typically 0W-40, 5W-40, or 5W-50 synthetic engine oil meeting MB 229.3, 229.5, or 229.51 specifications.

Transmission
Standard
Transmission Type Early W463:	5-speed automatic transmission (e.g., 722.6 '7G-TRONIC' for some later models, earlier models used 4-speed automatics like 722.3/722.4).
Optional
Transmission Type Manual:	Less common in later W463, but manual transmissions were available in earlier G-Wagens.
Features
Transfer Case:	Permanent all-wheel drive with a two-speed transfer case and lockable differentials (center, rear, and front) activated electronically.
Fluid Specifications
Automatic Transmission Fluid:	MB 236.10, 236.12, or 236.14 ATF (e.g., Shell ATF 134, Febi Bilstein equivalent) depending on transmission type.
Transfer Case Fluid:	Typically SAE 75W-85 or 75W-90 GL-4 or GL-5 gear oil.
Gear Ratios
Final Drive Ratios:	Varies by model and axle ratio, common ratios include 4.375:1 or similar for enhanced off-road capability.

Dimensions
Exterior
Length:	Approx. 4575 mm (standard wheelbase)
Width:	Approx. 1810 mm (excluding mirrors)
Height:	Approx. 1931 mm
Wheelbase:	Approx. 2850 mm
Weights
Curb Weight:	Approx. 2100 kg to 2500 kg depending on engine and equipment.
Gross Vehicle Weight Rating:	Approx. 2800 kg to 3200 kg.
Cargo
Cargo Volume:	Approx. 1500 liters (with rear seats folded).
Wheels And Tires
Standard Tire Size:	Commonly 265/70 R16, 265/65 R17, 275/55 R19, 275/50 R20 depending on trim and year.
Bolt Pattern:	5x130 mm
Center Bore:	84.1 mm

Safety Features
Ratings
NHTSA Rating:	Not typically rated by NHTSA in a comparable manner to modern SUVs due to its niche and older design origins. Focus is on intrinsic ruggedness and active safety systems.
Active Features
Traction Control:	All-wheel drive, electronic traction system (ETS), ASR (Anti-Slip Regulation)
Stability Control:	Electronic Stability Program (ESP) introduced in later W463 models.
Braking System:	4-wheel disc brakes, ABS (Anti-lock Braking System), Brake Assist (BAS)
Passive Features
Airbags:	Front airbags, side airbags (front, and rear in later models), optional curtain airbags.
Chassis Construction:	Ladder frame chassis (throughout most of W463 generation, though more integrated into body for later models) providing inherent robustness and off-road durability.

Technology Features
Infotainment
Infotainment System:	COMAND (Cockpit Management and Navigation) system, with integrated navigation, radio, CD/DVD player, and optional TV tuner. Later models feature updated COMAND systems with larger screens and more advanced features.
Audio System:	Bose premium sound system often available as an option.
Driver Assistance
Cruise Control:	Standard cruise control, with DISTRONIC adaptive cruise control available on later models.
Parking Assistance:	Front and rear parking sensors, rearview camera on later models.
Connectivity
Bluetooth:	Available for hands-free calling and audio streaming on later models.
Usb Aux Input:	Available in later iterations of the W463.

Maintenance
Service Intervals
Oil Change Interval:	Typically every 15,000 km or 12 months, whichever comes first (subject to driving conditions and specific engine).
Major Service Interval:	Spark plugs, transmission service, coolant flush, differential oil change at varying intervals, often around 60,000 km to 100,000 km.
Fluid Specifications
Brake Fluid:	DOT 4 or DOT 4 Plus specification brake fluid.
Power Steering Fluid:	MB Specification 343.0 or equivalent power steering fluid.
Coolant Capacity:	Approximately 10-12 liters depending on engine and cooling system configuration.
Known Issues
Common Wear Items:	Wheel bearings, suspension bushings, flexible brake hoses, exhaust system components, stepper motor in HVAC controls, certain electronic sensors.
Engine Specific Issues:	V6/V8 engines can experience intake manifold failures or oil leaks from valve cover gaskets. Diesel engines may have issues with glow plug control modules or EGR systems.
Electrical Gremlins:	As with many complex German vehicles of this era, occasional electrical issues related to modules or wiring harnesses can occur.
Filter Part Numbers Examples
Oil Filter Example:	Mann-Filter HU 721/4 y, Mahle OX 34/1D, Mercedes-Benz A0001802609 (specific to engine).
Air Filter Example:	Mann-Filter C 30 120, Mercedes-Benz A2720900000 (specific to engine).

Vehicle History
Brand Heritage
Mercedes Benz History:	Founded in 1926, Mercedes-Benz has a long-standing reputation for luxury, engineering excellence, and pioneering automotive technologies.
Model Evolution
G Class Origin:	Originally developed in the 1970s for military use, the civilian G-Wagen was introduced in 1979. The W463 generation, introduced in 1989, marked a significant shift towards luxury and comfort while retaining off-road capability.
Production
W463 Production Years:	1989-2018 (pre-facelift and facelifted versions)
Manufacturing Location:	Graz, Austria (by Magna Steyr)
Sales Figures
Global Sales Trend:	Consistent demand globally, particularly in luxury markets and regions valuing off-road capability. Sales increased significantly with updates and performance variants.

Awards & Recognition
Recognitions
Off Road Awards:	While not typically receiving formal 'awards' in the consumer sense, the G-Class is consistently recognized as one of the most capable off-road vehicles ever produced, with a legendary status in off-road communities and among automotive journalists.
Ratings
Reliability Ratings:	Variable. Early W463 models are known for robust mechanicals but can have electrical issues. Later models generally improved, but overall reliability often ranks below Japanese competitors due to complexity and premium nature.
Certifications
Emissions Standards:	Meets Euro 4, Euro 5, and Euro 6 emissions standards depending on model year and market. Manual will detail specific testing procedures and specifications.