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Mercedes-Benz Maintenance Manual Cross-country Vehicle | Volume 1 (Supplement 6)
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Mercedes-Benz G-Class W460, W461 and W463 maintenance manual | Volume 1
Mercedes-Benz maintenance manual for Cross-country Vehicle models, especially useful for service, inspection, lubrication and regular maintenance work on G-Class W460, W461 and W463 vehicles.
English PDF | 301 pages | Immediate digital delivery.
- Mercedes-Benz Maintenance Manual Cross-country Vehicle Volume 1
- Includes Supplement 6 with revisions and model updates up to 1993
- Covers W460, W461 and W463 models, including gasoline and diesel versions
- Contains maintenance intervals, filling capacities, service products and tightening torques
- Ideal for preventive maintenance, inspection and technical service of Mercedes-Benz G-Class vehicles
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Mercedes Benz Maintenance Manual Cross-country Vehicle | Volume 1 (Supplement 6) | PDF
Technical maintenance manual for Mercedes-Benz Cross-country Vehicle models, especially useful for service, inspection, lubrication, preventive maintenance and regular checks on G-Class W460, W461 and W463 vehicles.
This edition corresponds to the Mercedes-Benz Maintenance Manual Cross-country Vehicle Volume 1 and includes Supplement 6, with revisions and additions published in September 1993.
The manual brings together scheduled maintenance jobs, service intervals, inspections, leak checks, lubrication, fluid replacement, adjustments, test data and procedures organized by technical groups and job numbers.
According to the manual preface, each maintenance job is identified by a four-digit work item number, allowing each task to be quickly linked to its corresponding technical group.
Supplement 6 includes revisions, updated technical data and additional models from the 461 and 463 series, including 230 GE, 290 GD, 350 GD Turbo and 500 GE V8.
The scope of the manual can be reviewed in more detail in the Full index tab, where the included technical groups, job numbers and operations are listed.
Main topics covered in the Mercedes-Benz Cross-country Vehicle maintenance manual
- Mercedes-Benz W460, W461 and W463 model survey
- Maintenance intervals up to 8/93 and as of 9/93
- Inspection, lubrication service and regular maintenance
- Test data, filling capacities, service products and tightening torques
- Special tools and commercially available tools
- Leak and condition checks for units, lines, hoses and components
- Engine oil and filter change for gasoline and diesel engines
- Valve adjustment, diesel injection system, carburetor and gasoline injection system
- Air cleaner, belts, engine cooling system and coolant replacement
- Clutch, manual transmission, automatic transmission and transfer case
- Pedals, clutch operation, differential lock operation and throttle control
- Frame, suspension, shock absorbers, stabilizers and mountings
- Front axle, rear axle, wheel hubs, bearings and universal joint housings
- Wheels, tires, tire pressure, wear and damage checks
- Propeller shaft, universal joints and sliding elements
- Brakes, brake fluid, brake pads, wear checks, bleeding and brake testing
- Manual steering, power steering, steering play and steering linkage
- Fuel system, electrical system, instruments, lamps and battery
- Body, doors, sliding roof, windshield wipers, climate control, seats and paintwork
Models included in this Mercedes-Benz manual:
- W460 Series: 200 GE, 230 G, 230 GE, 280 GE, 240 GD, 250 GD and 300 GD
- W461 Series: 230 GE and 290 GD
- W463 Series: 200 GE, G 200, 230 GE, G 230, 300 GE, G 300, 500 GE V8, 250 GD, 300 GD, G 300 Diesel, 350 GD Turbo and G 350 Turbodiesel
Important: This manual corresponds to the Mercedes-Benz Maintenance Manual Cross-country Vehicle Volume 1 and includes Supplement 6. To apply each procedure correctly, always verify the exact model, series, chassis number, engine, transmission, body, year, equipment and corresponding specification.
The digital edition allows quick access to the operations through internal bookmarks, making it easier to search by technical group, job number, system or model from a computer, tablet or mobile phone.
Item features:
- Format: PDF
- Language: English
- Pages: 301
- Delivery method: Download link
Frequently asked questions
Does this manual apply to the Mercedes-Benz G-Class?
Yes. The manual is dedicated to Mercedes-Benz Cross-country Vehicle models, the designation used for G-Class off-road vehicles from the W460, W461 and W463 series.
What does Supplement 6 mean?
Supplement 6 is an update to Volume 1 published in September 1993. It includes revisions, additions and later model updates, including selected W461 and W463 models.
What type of technical information does it include?
It includes maintenance intervals, inspection operations, lubrication, fluid replacement, leak checks, adjustment data, filling capacities, service products, tightening torques and tools.
Does it cover gasoline and diesel models?
Yes. It includes gasoline models such as 200 GE, 230 GE, 280 GE, 300 GE and 500 GE V8, as well as diesel versions such as 240 GD, 250 GD, 290 GD, 300 GD and 350 GD Turbo.
Is this a complete repair workshop manual?
No. This is not a full general disassembly workshop manual. It is focused on maintenance, inspection, lubrication, regular service and technical checks, with procedures organized by work item numbers.
Is it useful for restoring or preserving a classic Mercedes-Benz G-Class?
Yes. It is especially useful for properly maintaining a classic G-Class, checking pending service work, reviewing maintenance intervals and following factory procedures for periodic technical operations.
Mercedes-Benz W460, W461 and W463 Maintenance Manual | Volume 1 | Index
This index lists the technical groups, job numbers and operations included in the Mercedes Benz Maintenance Manual Cross-country Vehicle | Volume 1 (Supplement 6).
Each entry is listed in accordance with the manual’s original technical layout and numbering.
Preliminary pages
- Preface
- Group survey
- Vehicle survey Model 460
- Vehicle survey Model 461
- Vehicle survey Model 463
- Maintenance intervals
- Contents
00 General job nos.
- 0050 All units - Testing for leaks and condition
- 0051 Lines and hoses - Checking condition and testing for leaks
- 0053 Visual inspection for leaks - Assemblies, chafing points, hose routing, components
01 Cylinder crankcase, cylinder head
- 0101 Engine - Oil and filter change
05 Engine timing, valves
- 0560 Adjusting valve clearance
07 Diesel injection system, carburetor system, gasoline injection system
- 0711 Stromberg carburetor - Checking and correcting oil level in damper
- 0750 Checking and adjusting idle speed
- 0753 Fuel prefilter - Checking and renewing
- 0770 Carburetor flange - Checking and retightening screws
- 0780 Replacing fuel filter
09 Air cleaner
- 0931 Air cleaner with dust extraction valve - Emptying dust
- 0950 Air cleaner with paper element - Checking soiling. Cleaning or replacing if necessary
- 0980 Air cleaner with paper element - Replacing element
13 Belt drives
- 1350 V-belts - Checking condition and tension, adjusting tension
- 1351 Ribbed V-belts - Checking condition
14 Intake manifold, exhaust manifold
- 1470 Checking and tightening mounting nuts
15 Electrical system, engine
- 1550 Spark plugs - Visual examination, checking electrode gap. Replacing as required
- 1551 Examining contact breaker points. Replacing as required
- 1554 Checking and adjusting firing point
- 1560 Adjusting dwell angle
- 1561 Ignition timing, adjust
- 1571 Alternator - Checking tightness of mounting nuts and bolts, retightening
- 1580 Replacing spark plugs
- 1581 Replacing contact breaker points
20 Engine cooling
- 2010 Engine cooling system - Checking and correcting fluid level - Checking anticorrosion / antifreeze
- 2011 Engine cooling system - Checking and correcting fluid level
- 2050 Cooling and heating system - Checking condition and for leaks
- 2080 Replacing coolant
- 2081 Replacing cooling and heating water hoses
22 Engine mounts
- 2292 Releasing engine mounts
25 Clutch
- 2590 Clutch housing - Draining fluid
26 Manual transmission, power take-offs
- 2601 Oil change
- 2610 Checking and correcting oil level
27 Automatic transmission
- 2702 Oil and filter change
- 2710 Checking and correcting oil level
- 2790 Converter housing - Draining fluid
28 Transfer case
- 2801 Oil change
- 2810 Checking and correcting oil level
29 Pedals
- 2910 Clutch operating mechanism - Checking and correcting fluid level
- 2912 Differential lock operating mechanism - Checking and correcting fluid level
- 2950 Clutch actuation system - Checking condition and for leaks
- 2953 Differential lock operating mechanism - Checking condition and testing for leaks
- 2981 Clutch operating mechanism - Replacing brake fluid
- 2982 Differential lock operating mechanism - Replacing brake fluid
30 Throttle control
- 3022 Engine regulating linkage and regulating shaft - Lubricating, checking for ease of movement and wear
- 3052 Idle adjuster - Checking and adjusting setting
31 Frame
- 3120 Lubricating trailer coupling
- 3151 Trailer coupling - Checking function, play and mounting
32 Suspension
- 3254 Shock absorbers - Checking condition and for leaks
- 3270 Stabilizers - Checking seating and tightening
33 Front axle
- 3301 Oil change
- 3310 Checking and correcting oil level
- 3321 Universal joint housing of all-wheel front axle - Checking and correcting grease filling
- 3350 Front axle wheel hubs - Renewing grease, checking taper roller bearing
- 3370 Control arm and trailing arm of front axle - Tightening nuts and bolts. Observe torque specification
- 3372 Front axle cover plate - Retightening bolts
35 Rear axle
- 3501 Oil change
- 3510 Checking and correcting oil level
- 3571 Rear axle control arm and trailing arm - Retightening nuts and bolts. Observe torque specification
- 3572 Rear axle cover plate - Retightening bolts
40 Wheels
- 4020 Lubricating spare wheel mounting
- 4051 Checking tires for damage and condition. Exchange wheels if necessary and invoice separately
- 4053 Checking tire wear
- 4060 Tire pressure - Correcting, include spare wheel
41 Propeller shaft
- 4121 Lubricating universal joints and sliding elements
42 Brakes
- 4210 Checking and correcting fluid level
- 4251 Disc brake - Checking brake pad thickness
- 4253 Checking brake lining wear
- 4280 Replacing brake fluid
- 4290 Testing brakes on test stand, test drive
46 Steering
- 4610 Manual steering - Checking and correcting oil level
- 4611 Power steering - Checking and correcting oil level
- 4650 Checking steering play, checking play and condition of steering linkage
- 4671 Steering fastening - Checking that bolts are secure, tightening
47 Fuel system
- Checking condition and testing for leaks
49 Exhaust system
- 4970 Exhaust flange - Checking that nuts are secure, tightening
54 Electrical system - Equipment and instruments
- 5410 Batteries - Checking and correcting electrolyte level
- 5451 Signals and indicator lamps - Operational check
60 Body, general
- 6070 Body fastening to frame - Checking that nuts and bolts are secure, tightening
72 Doors
- 7220 Lubricating door hinges
77 Roof hydraulics, sliding roof
- 7730 Sliding roof - Cleaning and lubricating guide rails and guide shoes
82 Electrical system - Body
- 8210 Windshield washer system - Checking and correcting fluid level
- 8231 Cleaning telescopic antenna rod
- 8251 Headlamps and exterior lamps - Checking operation
- 8252 Windshield wipers, windshield washer system and headlamp cleaning system - Function test
- 8260 Headlamps - Checking and adjusting setting
- 8280 Replacing rubber wiper blade for windshield wiper
83 Climate control
- 8312 Air conditioner - Checking refrigerant level
- 8332 Air conditioner - Checking evaporator at air intake, cleaning if necessary
- 8351 Heating and ventilation, auxiliary heater - Checking operation
88 Attached parts, outside flaps
- 8821 Lubricating hood lock
91 Seats
- 9150 Checking seat belts for damage
98 Paintwork
- 9850 Checking body for paintwork damage
Mercedes-Benz Maintenance Manual Cross-country Vehicle Volume 1 | Maintenance manual cover