2006 Mercedes G-Class (W463) Service and Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Generation Code: W463 Model Year: 2006 Codes Chassis Code: W463 👋 Introduction Market Position Positioning: Premium luxury SUV, renowned for off-road capability and build quality Competitive Analysis Competitors: Land Rover Range Rover, Toyota Land Cruiser, Lexus LX Key Features Design Philosophy: Rugged, utilitarian construction combined with Mercedes-Benz luxury and engineering Off Road Capability: Three independently locking differentials, robust chassis, excellent ground clearance 📋 Manual Details Coverage Areas Primary Coverage: All Models and All Repairs A-Z Target Audience: Dealership Technicians, DIY Enthusiasts Page Count Estimated Pages: N/A (Digital Format) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Digital Compatibility: Windows (Vista 32/64, XP, ME, 98, NT, 2000), Mac 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul Control System: Engine control module (ECM) diagnostics and programming Mechanical: Engine mechanical components, chassis, body Fuel Service: Fuel system diagnostics, repair, injection system specifications Emission Control: Emission control system diagnosis and repair Intake Exhaust Cooling: Cooling system diagnostics, repair, exhaust system service Lube: Lubrication system specifications and maintenance Ignition Starting Charging: Ignition system, starting system, charging system diagnostics and repair Auto Transmission: Automatic transmission service, diagnostics, repair Manual Transmission: Manual transmission service, diagnostics, repair Transfer Case: Transfer case service, diagnostics, repair Drive Shaft: Drive shaft and universal joint service Differential: Differential service, repair, and specifications Axle Suspension: Front and rear axle, suspension system diagnostics and repair Tire Wheel: Tire and wheel specifications, alignment procedures Brake Control: Brake system control units, ABS, ESP diagnostics and repair Brake: Hydraulic brake system diagnostics, repair, component replacement Parking Brake: Parking brake system service and adjustment Steering Column: Steering column diagnostics and repair Power Steering: Power steering system diagnostics and repair Air Conditioning: HVAC system diagnostics, refrigerant handling, repair Supplemental Restraint: SRS (Airbag) system diagnostics, calibration, and repair Seat Belt: Seat belt system inspection and replacement Immobilizer: Engine immobilizer system diagnostics and programming Cruise Control: Cruise control system diagnostics and repair Wiper Washer: Wiper and washer system service and repair Door Lock: Door lock and central locking system diagnostics and repair Meter Audio Visual: Instrument cluster, audio system, and infotainment diagnostics Horn: Horn system service and repair Windshield Glass Mirror: Windshield, glass, and mirror service and replacement Instrument Panel: Instrument panel removal, installation, and repair Seat: Seat adjustment mechanisms, seat heating system repair Engine Hood Door: Hood and door mechanism service and adjustment Exterior Interior: Exterior trim, interior trim, body panels Electrical: Comprehensive electrical system diagnostics, component testing Multiplex Can Communication: CAN bus network diagnostics and troubleshooting Procedures Included Maintenance: Routine checks, fluid changes, filter replacements Diagnostics: Step-by-step troubleshooting guides for all systems Repair: Detailed repair procedures for all major and minor components Component Replacement: Instructions for replacing individual parts and assemblies Wiring Schematics: Complete and detailed wiring diagrams for all circuits Illustrations Diagrams: High-quality illustrations and exploded view diagrams Torque Specifications: Detailed torque values for all fasteners during assembly and disassembly. Troubleshooting Charts: Diagnostic flowcharts for common problems and symptom-based troubleshooting. Fluid Capacities: Exact fluid capacities for engine, transmission, differentials, cooling system, etc. Electrical Component Testing: Resistance, voltage, and continuity testing procedures for all electrical components. Technical Depth Depth: Factory-level, technician-grade detail Data Accuracy: Vehicle-specific, not generic 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Printability: All pages printable Image Resolution: Allows image blowing up for enlarged copies Binding Type Binding: N/A (Digital - no physical binding) Paper Type Paper Type: N/A (Digital - no physical paper) ⚙️ Engine Specifications Primary Engine Engine Options 2006: V8 5.0L (M113), V12 5.5L (M275 - AMG models), possibly Diesel variants (OM628/OM642 depending on market) Performance Horsepower Range: Approx. 292 hp (G 500) to 500 hp (G 55 AMG) Torque Range: Approx. 336 lb-ft (G 500) to 516 lb-ft (G 55 AMG) Fuel System Fuel Injection: Multi-point fuel injection (MPI) 🔧 Transmission Standard Transmission Type Standard: 5-speed automatic (722.6 series) Optional Transmission Type Optional: Possibly 5-speed manual (earlier models), 7-speed automatic (722.9 series) for later W463 variants or specific AMG models, though 5-speed auto was common for 2006 Features Transfer Case Features: Permanent four-wheel drive with three electronically locking differentials (center, front, rear) 📐 Dimensions Exterior Wheelbase: Approx. 2850 mm (112.2 in) for standard wheelbase Length: Approx. 4520 mm (178.0 in) for standard wheelbase Width: Approx. 1760 mm (69.3 in) Height: Approx. 1931 mm (76.0 in) Weights Curb Weight Range: Approx. 2100-2300 kg (4630-5070 lbs) Towing Capacity: Approx. 3500 kg (7716 lbs) 🛡️ Safety Features Ratings NHTSA Rating: N/A (Vehicle not extensively tested by NHTSA in this era for rating) Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Electronic Traction System (ETS) or 4-ETS Stability Control: Standard Electronic Stability Program (ESP) Passive Features Airbags: Front airbags, optional side airbags Chassis Construction: Body-on-frame construction for ruggedness and durability 💡 Technology Features...
Possibly 5-speed manual (earlier models), 7-speed automatic (722.9 series) for later W463 variants or specific AMG models, though 5-speed auto was common for 2006
Features
Transfer Case Features:
Permanent four-wheel drive with three electronically locking differentials (center, front, rear)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2850 mm (112.2 in) for standard wheelbase
Length:
Approx. 4520 mm (178.0 in) for standard wheelbase
Width:
Approx. 1760 mm (69.3 in)
Height:
Approx. 1931 mm (76.0 in)
Weights
Curb Weight Range:
Approx. 2100-2300 kg (4630-5070 lbs)
Towing Capacity:
Approx. 3500 kg (7716 lbs)
🛡️ Safety Features
Ratings
NHTSA Rating:
N/A (Vehicle not extensively tested by NHTSA in this era for rating)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Electronic Traction System (ETS) or 4-ETS
Stability Control:
Standard Electronic Stability Program (ESP)
Passive Features
Airbags:
Front airbags, optional side airbags
Chassis Construction:
Body-on-frame construction for ruggedness and durability
💡 Technology Features
Infotainment
Infotainment System:
COMAND (Cockpit Management and Navigation) system with CD player, optional navigation, and radio.
Driver Assistance
Driver Assistance Features:
Standard ESP and traction control. Advanced driver assistance systems were less common in 2006 compared to modern vehicles.
Connectivity
Connectivity Options:
Limited by modern standards; primarily focused on audio and navigation via COMAND system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles (15,000-25,000 km) or 12 months, refer to specific engine type and manual
Transmission Fluid Change:
Every 60,000-100,000 miles (100,000-160,000 km), depending on driving conditions and transmission type
Spark Plug Replacement:
Varies by engine, typically 60,000-100,000 miles
Fluid Specifications
Engine Oil Spec:
MB 229.5 (e.g., 5W-40, 0W-40 synthetic)
Transmission Fluid Spec:
MB 236.10 or MB 236.12 (for 722.6 transmission)
Coolant Spec:
MB 325.0 or MB 326.0 (Ethylene Glycol based, blue/green)
Known Issues
Common G Class Issues:
Differential lock actuator failures, rust on body panels (especially around wheel arches and door sills), fuel pump issues, window regulator failures, HVAC blower motor issues.
📚 Vehicle History
Brand Heritage
Mercedes Benz History:
Pioneering automotive manufacturer with a legacy of luxury, engineering, and innovation.
Model Evolution
W463 Introduction:
The W463 generation was introduced in 1989, offering increased comfort and luxury over the military-derived W460/W461 series, while retaining legendary off-road prowess.
2006 Update:
The 2006 model year falls within a significant facelift period for the W463, which saw updates to engines, interiors, and technology features throughout its lifecycle.
Production
Manufacturing Location:
Graz, Austria (by Magna Steyr)
Production Years W463:
1989 - Present (with continuous updates)
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently recognized for its off-road capability and durability by automotive publications and enthusiasts.
Ratings
Consumer Satisfaction:
Generally high, particularly for build quality and longevity, though maintenance costs can be a factor.