Mercedes-Benz 463 Service Manual

Introduction of the New G-Class

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Model series 463

Introduction into Service Manual

Mercedes-Benz Service

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Introduction of the New G-Class

Model series 463

Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart

Information and copyright

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Product Portfolio

Comprehensive information about our full Product Portfolio
can also be found at our Internet Portal.
Link: http://aftersales.mercedes-benz.com

Questions and suggestions

If you have any questions or suggestions concerning this product, please write
to us.
E-mail: [e-mail]
Fax: [phone]

© 2012 by Daimler AG

This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIS, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including
databases and online services.

Image no. of title image: P00.00-4832-00
Image no. of posters: P00.00-4830-00

Order no. of this publication: 6516 1391 02 – HLI 000 000 07 96

03/2012

Contents

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Preface 6

Overview

Models and major assemblies 7

Brief description 8

Equipment 9

Overall vehicle

Exterior 15

Dimensions of G 350 BLUETEC 18

Dimensions of G 63 AMG 20

Technical data 22

Roof systems 24

Interior 25

Powerplant

Engine data for gasoline engines 30

Engine data for diesel engines 31

Gasoline engines M 157 AMG and M 273 32

Diesel engine OM 642 34

Engine cooling 36

Exhaust system 37

Fuel system 39

Transmission

Transmission data 43

Introduction of the New G-Class, Model Series 463

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Contents

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Chassis

Steering 45

Axles 46

Suspension 47

On-road/off-road characteristics 48

Brake system 50

Wheels and tires 52

Networking

Overall network 53

Batteries and alternator 57

Lights

Exterior lights 58

Interior lights 59

Safety

Active/passive safety

60

Restraint systems 61

Driving assistance systems

Overview of systems 62

Comfort

Climate control 63

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Introduction of the New G-Class, Model Series 463

Contents

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Audio and communications

Telematics 64

Sound system 65

Digital Owner's Manual 66

Body

Bodyshell 69

Annex

Abbreviations 70

Index 72

Introduction of the New G-Class, Model Series 463

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Preface

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Dear Reader,

This Introduction into Service Manual presents the
new G-Class of the facelifted model series 463.

The purpose of this brochure is to acquaint you with
the technical highlights of this vehicle in advance of its
market launch. This brochure is intended to provide
information for people employed in service or mainte­nance/repair as well as for aftersales staff. It is
assumed here that the reader is already familiar with
the Mercedes-Benz model series currently on the
market.

In terms of the contents, the emphasis in this Intro­duction into Service Manual is on presenting new and
modified components and systems.

This Introduction into Service Manual is not intended
as an aid for repairs or for the diagnosis of technical
problems. For such needs, more extensive information
is available in the Workshop Information System (WIS)
and Xentry Diagnostics.

WIS is updated continuously. Therefore, the informa­tion available there reflects the latest technical status
of our vehicles.

This Introduction into Service Manual presents initial
information about the G-Class of model series 463.
The Introduction into Service Manual is not stored in
this form i n WIS. The contents of this b rochure are not
updated. No provision is made for supplements.

We will publicize modifications and new features in the
relevant WIS documents. The information presented in
this Introduction into Service Manual may therefore
differ from the more up-to-date information found in
WIS.

All information relating to technical data, equipment
and options is valid as of the copy deadline in January
2012 and may therefore differ from the current
production configuration.

Daimler AG

Technical Information
and Workshop Equipment (GSP/OI)

i Note

Information about the vehicles and about oper­ating the vehicle functions can also be found in the
interactive owner's manual on the Internet at:

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Introduction of the New G-Class, Model Series 463

www.mercedes-benz.de/betriebsanleitung

Models and major assemblies

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BR Model Engine Automatic

Market launch

7-speed transmission

G500

463.202 273.969 722.904 06/12

convertible

G500 463.236 273.969 722.904 06/12

G350BLUETEC 463.346 642.886 722.902 06/12

1

G550

G63AMG 463.272

463.237 273.969 722.904 08/12

157.984 722.905 06/12

463.273

2

Overview

1

USA and Canada only

Model series 463

Introduction of the New G-Class, Model Series 463

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7

Brief description

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Vehicle concept

Overview

The combination of a characteristic and timeless
design has made the G-Class into an unmistakable
cross-country vehicle.

The impressive appearance of the facelifted model
series 463, combined with new and more advanced
technology further improve the attractiveness of this
legendary classic.

Dimensional concept

With a vehicle length of 4257 mm for the convertible
and 4662 mm for the station wagon, the vehicle
remains true to its predecessor. Only the vehicle width
has increased by 48 mm compared to the predecessor
due to the new outside mirrors.

New features

Main features of the model refinement include:

• Introduction of the G 63 AMG

• ECO start/stop function (G 63 AMG only)

• Newly designed radiator grille and bumpers
(G 63 AMG only)

• Newly designed outside mirrors

• DISTRONIC PLUS

• Brake Assist (BAS)

• LED daytime running lamps

• Blind Spot Assist

• Front Parktronic

• New Telematics Generation (NTG) 4.5

• COMAND display with new freestanding 17.8 cm
central display

• Newly designed instrument cluster with color
display

• Center console with new, high-quality controls
such as the COMAND controller

• New "THERMATIC" automatic air conditioning

• 4-spoke multifunction steering wheel

• New wheel design

• Fuel system

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Introduction of the New G-Class, Model Series 463

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i Note

Further details on the electrical systems of model
series 463 (e.g. function descriptions and location
of electrical components) are available in WIS
under information type "Basic knowledge/func­tions" (GF).

Equipment

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G350

BLUETEC

Equipment variants

Exclusive package Code PA4 — —

designo Exclusive package — — — Code PA6

Sport package Code PA5 — —

Chrome package Code ZD6 Standard

Seating comfort package Code PA1

Exterior stainless steel package Code PA3

Powerplant, engine, suspension, brakes

G 500 G550 G63AMG

1

1

Standard Code PA1

Standard

Overview

ECO start/stop function — — — Standard

Diesel particulate filter (DPF) Standard — — —

Front and rear AMG brake calipers painted
silver instead of red

Wheels, tires, light alloy wheels

40.64 cm (16") light alloy wheel
"Star design"
265/70; 7.5 J x 16 ET63

45.72 cm (18") light alloy wheel
"High-sheen machined"
265/60; 7.5 J x 18 ET63

— — — Code BS1

Standard

Code RL3

Code RL6 — —

— — —

1

Standard in Japan

Introduction of the New G-Class, Model Series 463

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Equipment

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Overview

Wheels, tires, light alloy wheels

45.72 cm (18") light alloy wheel
"5-hole design"
265/60; 7.5 J x 18 ET63

45.72 cm (18") light alloy wheel
"5 double-spoke design"
265/60; 7.5 J x 18 ET63

50.80 cm (20") light alloy wheel
AMG "Titanium gray, 5-spoke design"
275/50; 9.5 J x 20 ET50

50.80 cm (20") light alloy wheel
AMG "Matt black, 5-spoke design"
275/50; 9.5 J x 20 ET50

G350

G500 G550 G63AMG

BLUETEC

Code RL5 —

Code RM9 Standard —

— Standard

Code R10

— Code R11

Tire pressure monitor Code RY6 Code RY6

1

Roof systems

Electrically powered sliding roof

1

Code D27 Code D27

2

Climate control

2-zone automatic air conditioning Standard

Stationary heater incl. remote control Code H12 Code H12

1

Except Japan

2

Standard in Japan

3

Except Japan

3

Standard Code RY6

Standard Code D27

— Code H12

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Introduction of the New G-Class, Model Series 463

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Equipment

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G350

G 500 G550 G63AMG

BLUETEC

Light systems

Bi-xenon headlamps with automatic head-

Standard
lamp range adjustment and headlamp
cleaning system

Oval front fog lamps with integrated corner-

Standard —

ing lights function

LED daytime running lights Standard

Headlamp Assist Standard

Ambiance illumination Standard

Overview

Driving assistance systems

Parktronic Code EZ8 Code EZ8

1

Standard Code EZ8

DISTRONIC PLUS Code EZ9 Standard Code EZ9

Brake Assist (BAS) Standard

Cruise control with Variable Speed Limiter Standard

Reversing camera

1

Standard in Japan

2

Not valid for G 500 convertible

2

Code FR8 Code FR8

1

Standard Code FR8

Introduction of the New G-Class, Model Series 463

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Equipment

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Overview

Interior equipment

Multifunction steering wheel Standard

Heated multifunction steering wheel (only in
combination with leather steering wheel

Leather upholstery, black Code SP3 Standard —

Leather upholstery, gray Code SP4 —

Leather upholstery, chestnut Code SP5 —

Leather-clad instrument panel (black) Code JC9

designo trim, piano lacquer, black Code ZG2 Standard

G350

BLUETEC

G500 G550 G63AMG

Code VL0

2

1

Standard Standard

designo trim, carbon Code ZG6

1

Except Japan

2

Except Japan, standard on right-hand drive vehicles

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Introduction of the New G-Class, Model Series 463

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Equipment

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G350

G 500 G550 G63AMG

BLUETEC

Comfort systems

Electrically adjustable front seats incl.

Standard
4-way lumbar support

Seat heaters for driver and front passenger Standard

Heater for rear bench seat

1

Standard

Safety and theft protection

Airbags for driver and passenger Standard

Windowbag Standard

1

Anti-theft alarm system (ATA) — — Standard —

Overview

ATA with tow-away protection and interior
monitoring

Neck-Pro luxury head restraints, crash­active

1

Not valid for G 500 convertible

2

Standard in Japan

Code FZ8 Code FZ8

1,2

Standard

— Code FZ8

Introduction of the New G-Class, Model Series 463

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Equipment

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Overview

Telephone, audio and communications

HD radio — — Standard Standard

Surround sound system
(harman/kardon

COMAND Online Standard

Digital Audio Broadcasting (DAB) Code EF6 Code EF6

Comfort telephony Code EH2 Code EH2

Media interface Code EH3 Code EH3

Rear entertainment

®

Logic 7®)

6

G350

G500 G550 G63AMG

BLUETEC

1

2

Code EU9

3

Code EU9

3

2

4

5

Standard Code EU9

— Code EF6

— Code EH2

Standard Code EH3

3

Code EM7

TV tuner

1

Code EM8 — Code EM8

Miscellaneous

115V socket — — Standard —

Ball head trailer hitch Code Q55 Code Q55

4

— Code Q55

Trailer socket (13-pin) Standard

1

USA only

2

Not valid for G 500 convertible and Japan

3

Standard for right-hand drive vehicles

4

Except Japan

5

Standard in Japan

6

Not valid for G 500 convertible

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Introduction of the New G-Class, Model Series 463

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Front view

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Exterior

The functional, robust front view of the G-Class has
retained its character for decades.

One of the most important features of the front design
is the radiator grille with three slats and a large central
star.

Underneath the bi-xenon main headlamps with auto­matic headlamp range adjustment and headlamp
cleaning system, additional LED daytime running
lamps decorate the front of the G-Class.

The already striking brush guard (SA, except ECE) of
the G-Class has been modified accordingly to the new
exterior lights concept. On vehicles with this option,
the stone chipping protection grilles are omitted.

The G-Class also features new outside mirrors. These
produce less aerodynamic drag and provide signifi­cantly improved aeroacoustics.

The radar unit of the Distronic system, optionally avail­able as special equipment, is located in the front
bumper on the left-hand side underneath the radiator
grille.

The AMG variant features a chrome radiator grille with
two slats. In contrast to the standard model, the front
bumpers are made of plastic and no front fog lamps
are installed. In addition, the ground clearance of the
G 63 AMG is reduced by 10 mm.

Overall vehicle

Front view

Introduction of the New G-Class, Model Series 463

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Exterior

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Side view

Clear lines and large flat areas distinguish the side
view of the G-Class. The station wagon is character-

Overall vehicle

ized by two large windows in the rear. The rocker
panels, beltline and roof edges run parallel to each
other.

The new outside mirrors with integrated turn signal
indicator and ambient illumination are painted in the
vehicle color and fold in electrically. The mirror setting
can be stored for up to three drivers via the memory
function.

The rub strip runs horizontally along the vehicle level
with the door handles and the distinctly shaped wheel
well liners provide a harmonious overall appearance
together with the striking and powerful design of the
light alloy wheels.

The AMG variant features additional fender flares in
the vehicle color as well as AMG trim strips made of
brushed aluminium with "AMG" and "V8 BITURBO"
logos on the front fenders. The chrome-plated, side­mounted dual tailpipes in an oval design (country­specific) give the AMG a striking overall appearance.

Side view

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Introduction of the New G-Class, Model Series 463

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Rear view

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Exterior

The distinct wheel well liners and wide track width give
the G-Class a robust and sturdy image. The main
elements of the rear design include the large left­hinged rear-end door as well as the full-size spare
wheel mounted on the rear-end door. When

50.80 cm (20") light alloy wheels are used, the
maximum size of the spare wheel is 48.26 cm (19").

The USA version features an additional reinforced
bracket for additional tank protection.

The oval rear lamps in classic rectangular lamp units,
the rear bumper with integrated rear fog lamp and
backup lamp as well as t h e stainless steel spare wheel
cover (in combination with Exterior stainless steel
package, SA) give the G-Class even greater visual
impact.

Overall vehicle

Rear view

Introduction of the New G-Class, Model Series 463

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Dimensions of G 350 BLUETEC

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Overall vehicle

Vehicle dimensions of G 350 BLUETEC

Dimensions unloaded

1 At permissible gross vehicle weight

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Introduction of the New G-Class, Model Series 463

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Dimensions of G 350 BLUETEC

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Overall vehicle

Vehicle dimensions (garage dimensions) of G 350 BLUETEC

Dimensions unloaded

1 At permissible gross vehicle weight

Introduction of the New G-Class, Model Series 463

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Dimensions of G 63 AMG

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Overall vehicle

Vehicle dimensions of G 63 AMG

Dimensions unloaded
Vehicle without license plate adapter (6 mm)

1 At permissible gross vehicle weight

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Introduction of the New G-Class, Model Series 463

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P00.10-5200-00

Dimensions of G 63 AMG

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Overall vehicle

Vehicle dimensions (garage dimensions) of G 63 AMG

Dimensions unloaded
Vehicle without license plate adapter (6 mm)

1 At permissible gross vehicle weight

Introduction of the New G-Class, Model Series 463

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Technical data

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Comparison of model series 463 against model series 463 MOPF

Overall vehicle

Dimensions

Vehicle length mm 4257/4662

Vehicle width mm 1760 1760 0

Vehicle width
(with outside mirrors folded out)

Vehicle height mm 1951 1951 0

Wheelbase mm 2400/2850

Front overhang mm 783 783 0

Rear overhang mm 820 820 0

Unit 463 463

MOPF2012

1

4257/4662

1

0

mm 2007 2055 +48

1

2400/2850

1

0

Difference

Front track width mm 1475/15152

1475/1515

Rear track width mm 1475/15152 1475/1515

2

2

Front overhang angle ° 36 36 0

Rear overhang angle ° 27 27 0

Ramp angle ° 24/273

Coefficient of drag C

1

Long station wagon

2

Valid for G 550 USA

3

Valid for G 500 convertible

d

0.54 0.54 0

24/27

3

0

0

0

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Introduction of the New G-Class, Model Series 463

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