Mercedes G-Class W460 - Repair, Service and Maintenance Manual

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MERCEDES G-CLASS W460 - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Mercedes G-Class W460.

 CONTENTS:

- Group 01
- Installation survey
- Illustrations, Sectional views, Exploded views
- Special tools
- General engine data, Performance diagram
- Removal and instal lation of engine
- Checking cylinder for leaks
- Checking compression
- Removal and instal lation of cylinder head
- Pressure testing cylinder head
- Refacing cylinder head parting surface
- Renewing core-hole plug in cylinder crankcase
- Knocking out and inserting steel balls for main oil ducts
- Installation and centering of intermediate flange
- Removal and insta llation of complete oil pan
- Evaluation of cylinder bores
- Measuring. boring and honing cyl inder bores
- Facing cylinder crankcase parting surface
- Group 03
- Exploded views
- Removal and instal lation of flywheel and driven plate
- Refacing flywheel
- Static balancing of flywheel
- Renewing ring gear of flywheel
- Removal and installation of grooved ball bearing and cover ring in crankshaft
- Removal and installation of pulley and balancing disk
- Static balancing of balancing disk
- Renewing front crankshaft radial sealing ring
- Renewing rear crankshaft rad ial sealing ring
- Mounting of crankshaft
- Removal and installation of crankshaft sprocket
- Checking and reconditioning of crankshaft
- Removal and installation of pistons
- Reconditioning and squaring connecting rods
- Checking, renewing and tightening connecting rod bolts
- C1oss Coun1ry Vehicle
- 61 Contents Engine •115.973
- Group 05
- Exploded views
- Checking and adjusting of valve clearance
- Renewing threaded bushing with valve adjusting screw
- Renewing valve stem seals
- Refacing valve seats
- Removal and installation of valve springs
- Checking valve springs
- Checking and refacing valves
- Renewing valve seat rings
- Checking and renewing valve guides
- Removal and installation of rocker arms
- Checking and adjusting camshaft timing
- Removal and installation of chain tensioner
- Renewing timing chain
- Removal and installation of tension rail
- Removal and installation of slide rai ls
- Removal and installation of helical gear shaft
- Removal and installation of intermediate sprocket shaft
- Removal and installation of intermediate sprocket
- Removal and installation of camshaft
- Grinding camshaft bearing journals
- Group 07
- Illustrations, Exploded views
- Design and function description of Stromberg carburettor
- Troubleshooting Stromberg carburettor
- Adjusting engine
- Adjusting idle speed
- Checking and adjusting starting device
- Checking and adjusting CO values on dynamo meter
- Checking, removal and installation of fuel pump
- Cleaning carburettor. Adjusting float level
- Removal and installation of carburettor
- Adjusting basic sett ing of throttle valve
- Removal and installation of air piston, air piston diaphragm and metering rod
- Removal and installation of damper for air piston
- Pulldown function tests
- Checking pulldown diaphragm for leaks
- Removal, checking and installation of pulldown diaphragm
- Renewing driver lever in starting device.
- Checking function of starting device (cold start)
- Removal, checking and installation of starting device
- Checking and adjusting choke housing marking
- Checking function of idle cut-off valve, removal and installation
- Checking fuel return valve
- Group 09
- Design and function of intake air preheating
- Group 13
- Renewing and tensioning V-belt
- Group 15
- Testing ig nition system with tester
- Checking and adjusting dwell angle and firing point
- Renewing contact-breaker points
- Removal and installation of ignition distributor
- Group 18
- Checking oil pressure
- Removal and installation of oil filter element
- Disassembly and assembly of oil filter
- Removal and installation of oil pump
- Group 20
- Schematic diagram of coolant circuit, Exploded view
- Removal and installation of water pump
- Reconditioning
- Sealing water pump
- Removal and instal lation of water pump housing
- Cross Country Vehicle