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Mercedes Benz G wagen 460 280GE Factory Repair Manual

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๐Ÿท๏ธ Basic Information Identification Make: Mercedes-Benz Model: G-Wagen Chassis Code: W460 Engine Variant: 280GE Codes Internal Model Code: W460 ๐Ÿ‘‹ Introduction Market Position Segment: Premium, rugged, off-road capable SUV. Target Audience: Off-road enthusiasts, luxury SUV buyers seeking durability and capability, collectors of classic Mercedes-Benz vehicles. Competitive Analysis Competitors Era: Land Rover Defender, Toyota Land Cruiser (J60/J70 series), Range Rover Classic. Key Features Design Philosophy: Robust body-on-frame construction, exceptional off-road capability, legendary durability and build quality. Unique Selling Points: Triple locking differentials (optional), coil spring suspension, solid axles, exceptional approach/departure angles. Manual Value Proposition Benefit To Owner: Enables owners to perform all necessary maintenance and repairs, reducing reliance on specialized (and potentially expensive) service centers, and preserving the vehicle's longevity and capability. ๐Ÿ“‹ Manual Details Coverage Areas General Coverage: Comprehensive factory service and repair for the Mercedes-Benz G-Wagen 460 series, specifically the 280GE variant. Page Count Estimated Pages: Hundreds (precise count not specified, but implied to be extensive for factory manual). Manual Type Type: Factory Service Repair Manual Language Language: English (Implied for most international sales) Format Format: Downloadable PDF ๐Ÿ“– Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and specifications for the M102 2.8L inline-6 gasoline engine. Fuel System: K-Jetronic (CIS) fuel injection system, fuel pump, injectors, pressure regulator, air flow meter, cold start system, and emissions control. Ignition System: Ignition timing, distributor, coil, spark plugs, and electronic control unit (if applicable). Cooling System: Radiator, fan, water pump, thermostat, hoses, and coolant specifications. Lubrication System: Oil pump, oil filter, oil pan, lubrication passages, and oil specifications. Exhaust System: Exhaust manifolds, catalytic converter (if equipped), mufflers, and emissions components. Transmission: Manual and automatic transmission overhaul, repair, fluid specifications, and troubleshooting. Covers both 4-speed and 5-speed manual transmissions, and 4-speed automatic transmissions (e.g., 722.3). Drivetrain: Front and rear differentials, transfer case (including locking mechanisms), driveshafts, CV joints, and hub assemblies. Suspension: Front and rear suspension components, springs, shock absorbers, bushings, ball joints, tie rod ends, and alignment specifications. Steering: Power steering system, steering gearbox, steering column, and related components. Brakes: Front and rear brake systems (disc brakes), brake calipers, master cylinder, brake lines, parking brake, ABS components (if equipped), and fluid specifications. Electrical System: Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, and accessory circuits. Climate Control: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, and troubleshooting. Body And Chassis: Body panel removal and installation, frame inspection, doors, windows, seats, and interior trim. Wheels And Tires: Wheel specifications, tire sizes, and mounting procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication points, and belt inspections. Engine Repair: Engine assembly/disassembly, piston/ring replacement, cylinder head service, valve adjustments, crankshaft/camshaft service. Transmission Repair: Clutch replacement (manual), torque converter service (automatic), gear set replacement, seal and gasket replacement. Brake Service: Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper overhaul, bleeding procedures. Suspension And Steering Repair: Component replacement (shocks, springs, ball joints, tie rods), alignment procedures. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, component testing, and symptom-based diagnostics. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues across all vehicle systems. Torque Specifications: Detailed torque values for all critical fasteners across various systems. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth: Complete factory-level technical information, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures. ๐Ÿ“Š Manual Specifications File Format Format: PDF Print Quality Quality: Printable, allowing users to reproduce specific sections or the entire manual. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) โš™๏ธ Engine Specifications Primary Engine Engine Code: M102 Engine Type: Inline 6-cylinder, SOHC (Single Overhead Camshaft) Displacement: 2.8 Liters (2799 cc) Bore X Stroke: 86.0 mm x 80.25 mm Compression Ratio: 8.3:1 (typical) Performance Horsepower: Approx. 150 PS (148 hp) @ 5250 rpm (varies slightly by market and year) Torque: Approx. 230 Nm (170 lb-ft) @ 3250 rpm (varies slightly by market and year) Fuel System Injection System: Bosch K-Jetronic (Continuous Injection System - CIS) Fuel Type: Unleaded Gasoline (RON 91 / Octane 87 recommended) Cooling System Coolant Capacity: Approx. 10.5 Liters (with heater) Lubrication System Oil Capacity: Approx. 7.5 Liters (with filter) - Check manual for exact specification. Recommended Oil Viscosity: 10W-40 or 15W-40 (API SG or higher, consult manual for specific MB approval). ๐Ÿ”ง Transmission Standard Transmission Type: 4-Speed Manual (e.g., G320 manual transmission) Optional Transmission Type: 4-Speed Automatic (e.g., 722.3) Features Gear Ratios Manual: Refer to manual for specific ratios, typically includes low-range gearing. Gear Ratios Automatic: Refer to manual for specific ratios, typically includes low-range gearing. Fluid Capacity Manual Transmission Oil: Approx. 2.0 Liters (GL-4 or GL-5, consult manual for exact spec). Automatic Transmission Fluid: Approx. 8.0 Liters (Pan & Converter - ATF Dexron III or equivalent, consult manual for exact spec). ๐Ÿ“ Dimensions...
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Mercedes Benz G wagen 460 280GE Factory Repair Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Mercedes-Benz
Model:
G-Wagen
Chassis Code:
W460
Engine Variant:
280GE
Codes
Internal Model Code:
W460
๐Ÿ‘‹ Introduction
Market Position
Segment:
Premium, rugged, off-road capable SUV.
Target Audience:
Off-road enthusiasts, luxury SUV buyers seeking durability and capability, collectors of classic Mercedes-Benz vehicles.
Competitive Analysis
Competitors Era:
Land Rover Defender, Toyota Land Cruiser (J60/J70 series), Range Rover Classic.
Key Features
Design Philosophy:
Robust body-on-frame construction, exceptional off-road capability, legendary durability and build quality.
Unique Selling Points:
Triple locking differentials (optional), coil spring suspension, solid axles, exceptional approach/departure angles.
Manual Value Proposition
Benefit To Owner:
Enables owners to perform all necessary maintenance and repairs, reducing reliance on specialized (and potentially expensive) service centers, and preserving the vehicle's longevity and capability.
๐Ÿ“‹ Manual Details
Coverage Areas
General Coverage:
Comprehensive factory service and repair for the Mercedes-Benz G-Wagen 460 series, specifically the 280GE variant.
Page Count
Estimated Pages:
Hundreds (precise count not specified, but implied to be extensive for factory manual).
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (Implied for most international sales)
Format
Format:
Downloadable PDF
๐Ÿ“– Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, and specifications for the M102 2.8L inline-6 gasoline engine.
Fuel System:
K-Jetronic (CIS) fuel injection system, fuel pump, injectors, pressure regulator, air flow meter, cold start system, and emissions control.
Ignition System:
Ignition timing, distributor, coil, spark plugs, and electronic control unit (if applicable).
Cooling System:
Radiator, fan, water pump, thermostat, hoses, and coolant specifications.
Lubrication System:
Oil pump, oil filter, oil pan, lubrication passages, and oil specifications.
Exhaust System:
Exhaust manifolds, catalytic converter (if equipped), mufflers, and emissions components.
Transmission:
Manual and automatic transmission overhaul, repair, fluid specifications, and troubleshooting. Covers both 4-speed and 5-speed manual transmissions, and 4-speed automatic transmissions (e.g., 722.3).
Drivetrain:
Front and rear differentials, transfer case (including locking mechanisms), driveshafts, CV joints, and hub assemblies.
Suspension:
Front and rear suspension components, springs, shock absorbers, bushings, ball joints, tie rod ends, and alignment specifications.
Steering:
Power steering system, steering gearbox, steering column, and related components.
Brakes:
Front and rear brake systems (disc brakes), brake calipers, master cylinder, brake lines, parking brake, ABS components (if equipped), and fluid specifications.
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, and accessory circuits.
Climate Control:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, and troubleshooting.
Body And Chassis:
Body panel removal and installation, frame inspection, doors, windows, seats, and interior trim.
Wheels And Tires:
Wheel specifications, tire sizes, and mounting procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication points, and belt inspections.
Engine Repair:
Engine assembly/disassembly, piston/ring replacement, cylinder head service, valve adjustments, crankshaft/camshaft service.
Transmission Repair:
Clutch replacement (manual), torque converter service (automatic), gear set replacement, seal and gasket replacement.
Brake Service:
Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper overhaul, bleeding procedures.
Suspension And Steering Repair:
Component replacement (shocks, springs, ball joints, tie rods), alignment procedures.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, component testing, and symptom-based diagnostics.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems.
Torque Specifications:
Detailed torque values for all critical fasteners across various systems.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Technical Depth
Depth:
Complete factory-level technical information, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
๐Ÿ“Š Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
Printable, allowing users to reproduce specific sections or the entire manual.
Binding Type
Binding Method:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
โš™๏ธ Engine Specifications
Primary Engine
Engine Code:
M102
Engine Type:
Inline 6-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
2.8 Liters (2799 cc)
Bore X Stroke:
86.0 mm x 80.25 mm
Compression Ratio:
8.3:1 (typical)
Performance
Horsepower:
Approx. 150 PS (148 hp) @ 5250 rpm (varies slightly by market and year)
Torque:
Approx. 230 Nm (170 lb-ft) @ 3250 rpm (varies slightly by market and year)
Fuel System
Injection System:
Bosch K-Jetronic (Continuous Injection System - CIS)
Fuel Type:
Unleaded Gasoline (RON 91 / Octane 87 recommended)
Cooling System
Coolant Capacity:
Approx. 10.5 Liters (with heater)
Lubrication System
Oil Capacity:
Approx. 7.5 Liters (with filter) - Check manual for exact specification.
Recommended Oil Viscosity:
10W-40 or 15W-40 (API SG or higher, consult manual for specific MB approval).
๐Ÿ”ง Transmission
Standard
Transmission Type:
4-Speed Manual (e.g., G320 manual transmission)
Optional
Transmission Type:
4-Speed Automatic (e.g., 722.3)
Features
Gear Ratios Manual:
Refer to manual for specific ratios, typically includes low-range gearing.
Gear Ratios Automatic:
Refer to manual for specific ratios, typically includes low-range gearing.
Fluid Capacity
Manual Transmission Oil:
Approx. 2.0 Liters (GL-4 or GL-5, consult manual for exact spec).
Automatic Transmission Fluid:
Approx. 8.0 Liters (Pan & Converter - ATF Dexron III or equivalent, consult manual for exact spec).
๐Ÿ“ Dimensions
Exterior
Wheelbase:
2400 mm (Standard Wheelbase), 2850 mm (Long Wheelbase)
Overall Length:
Approx. 4000 mm (SWB) / 4340 mm (LWB)
Overall Width:
Approx. 1780 mm
Overall Height:
Approx. 1960 mm
Weights
Curb Weight:
Approx. 1900 - 2100 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 2800 kg
Wheels And Tires
Standard Tire Size:
205 R16, 215/75 R15 (common)
Wheel Bolt Pattern:
5 x 112 mm
Wheel Size:
15 or 16 inch
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available for this era of W460. Focus on inherent structural integrity.
Active Features
ABS:
Optional on some later models, but not standard on early W460 280GE.
Differential Locks:
Optional front, center, and rear locking differentials provide exceptional off-road traction and safety.
Passive Features
Seatbelts:
Standard front seatbelts; rear seatbelts vary by configuration and market. Manual will detail proper installation and adjustment.
Chassis Construction:
Body-on-frame construction with a rigid ladder chassis for durability.
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Basic factory AM/FM radio with cassette player. Aftermarket upgrades are common. Manual covers factory wiring.
Driver Assistance
ABS:
As mentioned, optional on later models. Not a significant feature for most W460 models.
Connectivity
Factory Options:
Limited to basic vehicle systems. No modern connectivity features (Bluetooth, USB, etc.) from factory.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km or annually (consult manual for specific mileage and driving conditions).
Filter Replacement:
Oil filter at every oil change. Air filter and fuel filter as per manual's schedule (typically every 20,000 - 40,000 km).
Spark Plug Replacement:
Typically every 20,000 - 40,000 km, depending on plug type (consult manual).
Transmission Fluid Change:
Manual: Every 40,000 - 60,000 km. Automatic: Every 50,000 - 80,000 km (or as specified in the manual).
Brake Fluid Change:
Every 2 years, regardless of mileage, to prevent moisture absorption.
Fluid Specifications
Engine Oil Spec:
Refer to manual for specific Mercedes-Benz approval numbers (e.g., MB-Approval 228.1 or 228.3 for diesel, 229.1 for gasoline, though 10W-40 SG is a common alternative). Manual will specify the correct type.
Coolant Spec:
Glysantin G05 (silicate-free) or equivalent, mixed 50/50 with distilled water. Consult manual for exact type and MB approval.
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid (consult manual for correct specification).
Brake Fluid:
DOT 3 or DOT 4 (consult manual for specific requirement).
Known Issues
Common Wear Items:
Bushings (suspension, body mounts), exhaust system, K-Jetronic fuel distributor, fuel pumps, ignition components, heater control valves.
Corrosion Prone Areas:
Wheel arches, rocker panels, tailgate lower edge, frame outriggers (especially in rust-belt regions). Manual will detail inspection points.
๐Ÿ“š Vehicle History
Brand Heritage
Manufacturer Legacy:
Mercedes-Benz has a long history of producing robust and durable vehicles, particularly for military and off-road applications, dating back to its origins.
Model Evolution
G Wagen Concept:
Developed in response to a request from the German military in the 1970s, prioritizing off-road capability, durability, and versatility. The W460 was the civilian and initial military version.
W460 Production Years:
1979 - 1993
280Ge Introduction:
Introduced in 1979 as a key gasoline engine option for the W460 chassis.
Production
Manufacturing Location:
Graz, Austria (Magna Steyr facility, contracted by Mercedes-Benz)
๐Ÿ† Awards & Recognition
Recognitions
Off Road Acclaim:
The G-Wagen series, including the W460, is universally recognized for its superior off-road capabilities and durability, often winning comparisons against contemporary SUVs.
Military Endorsement:
Widely adopted by military forces worldwide, a testament to its robustness and reliability under demanding conditions.
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