🏷️ Basic Information Identification Make: Mercedes-Benz Model: G-Class Chassis Code: W460 Specific Model Variant: 280GE Codes Engine Code: M102.938 👋 Introduction Market Position Positioning: The Mercedes-Benz G-Wagen (W460) is a legendary off-road vehicle, renowned for its ruggedness, durability, and distinctive utilitarian design. It has transcended its military origins to become a luxury icon, but its core engineering remains robust and requires specialized knowledge for maintenance and repair. Competitive Analysis Comparison To Competitors: Historically, the G-Wagen competed in the premium off-road segment against vehicles like the Range Rover, Jeep Grand Wagoneer, and Toyota Land Cruiser. Its unique combination of solid axles, differential locks, and Mercedes-Benz engineering set it apart. This manual provides the essential technical data to maintain this distinctiveness. Key Features Manual Value Proposition: This manual is the definitive resource for maintaining and repairing the Mercedes-Benz G-Wagen W460 280GE. Its comprehensiveness mirrors that used by Mercedes-Benz main dealers, ensuring accuracy and completeness for all service and repair tasks. It empowers owners and technicians with the knowledge to preserve the vehicle's iconic performance and longevity. 📋 Manual Details Coverage Areas Coverage Scope: All areas of repair, maintenance, and diagnostics Page Count Estimated Page Count: Extensive (Exact number not specified, implies comprehensive dealership-level documentation) Manual Type Type: Service and Repair Manual Language Language: English (Presumed, standard for international service manuals) Format Format: Digital Download (PDF, printable) Searchability: Searchable PDF format for efficient information retrieval. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, crankshaft, pistons, camshafts, timing system, lubrication system, cooling system, fuel injection system (KE-Jetronic) Engine Electrical: Ignition system, starter motor, alternator, engine control unit (ECU) diagnostics and wiring diagrams Transmission: Manual and automatic transmission service, overhaul, clutch system, torque converter Drivetrain: Transfer case, differentials (front and rear), axles, driveshafts, locking differentials (if equipped) Suspension: Front and rear suspension components, springs, shock absorbers, bushings, steering linkage Steering: Power steering system, steering gearbox, steering column, steering wheel Brakes: Front and rear brake systems (disc/drum configurations), hydraulic lines, master cylinder, brake boosters, parking brake Electrical System: Lighting system, power windows, central locking, dashboard instruments, wiring diagrams for all circuits Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, fuel injection system components Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, hangers Body And Chassis: Frame structure, body panels, doors, hoods, fenders, bumpers, interior trim, glass, seals Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation, step-by-step troubleshooting guides Repair And Overhaul: Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems Engine Rebuild: Complete engine overhaul procedures, including specifications for machining and tolerances Transmission Overhaul: Detailed steps for disassembling, inspecting, and rebuilding both manual and automatic transmissions Brake System Repair: Pad and rotor replacement, caliper service, brake bleeding, hydraulic component replacement Electrical Diagnostics: Use of multimeters, oscilloscopes, and diagnostic scan tools; interpretation of wiring diagrams for fault finding Bodywork And Paint: Panel replacement, dent repair, rust prevention and repair, glass replacement Torque Specifications: Precise torque values for all critical fasteners and components Diagnostic Tools: Guidance on using standard automotive tools and potentially specialized Mercedes-Benz diagnostic equipment of the era. Technical Depth Depth: Dealership Level - Comprehensive and highly detailed, suitable for professional technicians and serious DIY enthusiasts 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: High-resolution, printable pages for easy use in a workshop environment Binding Type Digital Binding: N/A (Digital download; user can print and bind) Paper Type Digital Paper Type Recommendation: Heavy-duty paper recommended for workshop use Completeness Content Coverage: Full coverage, designed for main dealer workshops, encompassing all aspects of vehicle service, repair, and diagnostics. ⚙️ Engine Specifications Primary Engine Engine Family: Mercedes-Benz M102 Engine Type: Inline-4 Cylinder, Spark Ignition, Naturally Aspirated Displacement: 2.8 Liters (2799 cc) Bore X Stroke: 103.0 mm x 80.2 mm Compression Ratio: 9.0:1 (Typical for M102.938) Valve Train: Overhead Camshaft (OHC), 2 valves per cylinder Performance Horsepower: 125 PS (92 kW) at 4750 rpm (Approximate, subject to market and specific tuning) Torque: 235 Nm (173 lb-ft) at 2800 rpm (Approximate) Fuel System Fuel Delivery: Bosch KE-Jetronic Fuel Injection (CIS-E) Fuel Type: Unleaded Gasoline (Octane rating appropriate for the era, typically 91 RON) Ignition System Ignition Type: Electronic Ignition System 🔧 Transmission Standard Standard Transmission: 4-Speed Manual Transmission (Optional 5-Speed Manual in later W460 variants) Optional Optional Transmission: 3-Speed Automatic Transmission (e.g., 722.3 or 722.4) Features Drivetrain Layout: Four-Wheel Drive (4x4), permanent or part-time depending on specific configuration Transfer Case: Two-speed transfer case with optional locking differentials (center and rear, sometimes front) 📐 Dimensions Exterior Wheelbase: 2850 mm (Standard wheelbase, for 280GE variant; shorter 2400mm and longer 3400mm also existed) Length: Approx. 4350 mm (for standard wheelbase variant) Width: Approx. 1760 mm Height: Approx. 1960 mm...