fuel cap MERCEDES-BENZ G500 2004 W463 Owner's Manual

Contents
Battery ............................................... 311
Charging the battery .................... 311
Disconnecting the battery ............ 312
Reconnecting the battery ............. 312
Jump starting ..................................... 313
Towing the vehicle ............................. 315
Transporting the vehicle............... 317
Towing the vehicle -
various problem scenarios ........... 317
Front towing eye .......................... 318
Rear towing eye ........................... 318
Freeing a stranded vehicle ........... 318
Fuses ................................................. 319
Fuse box in passenger
compartment ............................... 319
Fuse box in battery box................ 319
Fuse box in front passenger
footwell ........................................ 320
Fuse box in middle tunnel ............ 321
Technical data.................................. 323
Spare parts service............................. 324
Warranty coverage ............................. 325
Loss of Service and Warranty
Information Booklet ...................... 325
Identification labels ............................ 326
Layout of poly-V-belt drive .................. 327
G 500/G 55 AMG ......................... 327
Engine ................................................ 328
Rims and tires .................................... 329
Rims and Tires ............................. 329
Spare wheels ................................ 330
Electrical system ................................ 331
Main dimensions, vehicle weights
and ratings ......................................... 332
Main dimensions........................... 332
Vehicle weights and ratings .......... 332Fuels, coolants, lubricants, etc. .......... 333
Capacities ..................................... 333
Engine oils .................................... 334
Engine oil additives ....................... 335
Air conditioning refrigerant ........... 335
Brake fluid .................................... 335
Premium unleaded gasoline.......... 335
Fuel requirements......................... 336
Gasoline additives......................... 336
Coolants ....................................... 336
Anticorrosion/antifreeze .............. 337
Windshield/rear window washer
system and headlamp cleaning
system .......................................... 339
Consumer information........................ 340
Uniform tire quality grading .......... 340
Technical terms............................... 343Index................................................. 349

215 Operation
Driving instructions
Checklist before off-road driving
Engine oil level

Check the engine oil level
(page 229). The display
ENGINE OIL
LEVEL - OK
must appear in the multi-
function display.
Only then can the vehicle obtain a trou-
ble-free oil supply, even on steep gradi-
ents.
Tires


Check the tread depth and maintain
specified tire pressure (see tire pres-
sure label inside the fuel filler flap).


Check tires for possible damage and
remove foreign objects.


Replace missing valve caps.
iWhenever driving in off-road mode, we
recommend:

Keeping doors, tailgate, windows
and sliding/pop-up roof closed.


Switching cruise control off.
!Observe the following during off-road
driving:

Adjust vehicle speed to condition of
terrain. The more uneven, rutty and
steeper the terrain, the lower the
speed should be. Drive through wa-
ter slowly at an even speed, avoid-
ing a bow wave.


Be especially careful when driving
in unknown territory. It may be nec-
essary to get out of the vehicle and
scout the path you intend to take.


Watch out for obstacles, such as
rocks, holes, tree stumps and ruts.


Avoid excessive engine
speeds – drive at moderate engine
speeds (max. 3000 rpm).


Before driving through water, deter-
mine its depth.


Do not stop vehicle while immersed
in water, and do not shut off the en-
gine.


In sandy soil, drive at a steady
speed as allowed by conditions.
This helps overcome the vehicle
rolling resistance and reduces the
likelihood of the vehicle sinking into
the ground.


Do not initiate jumps with the vehi-
cle. It interrupts the forward mo-
mentum of the vehicle.


Always drive on slopes with the en-
gine running and the vehicle in
gear.


Inspect the vehicle for possible
damage after each off-road trip.

224 OperationAt the gas station
At the gas stationRefueling
The fuel filler flap is located on the
right-hand side of the vehicle towards the
rear. Locking/unlocking the vehicle with
the remote control automatically
locks/unlocks the fuel filler flap.

Turn off the engine.

Remove the SmartKey from the starter
switch.

Open the fuel filler flap by pushing at
the point indicated by the arrow.

Turn the fuel cap to the left and hold on
to it until possible pressure is released.

Take off the cap and set it in the recess
on the fuel filler flap.

To prevent fuel vapors from escaping
into open air, fully insert filler nozzle
unit.

Only fill your tank until the filler nozzle
unit cuts out – do not top up or overfill.

Replace the fuel cap by turning it to the
right.
You should hear the fuel filler cap en-
gage.

Close the fuel filler flap.
Warning!
G
Gasoline is highly flammable and poisonous.
It burns violently and can cause serious inju-
ry. Whenever you are around gasoline, avoid
inhaling fumes and skin contact, extinguish
all smoking materials. Never allow sparks,
flame or smoking materials near gasoline!
Failure to remove the fuel cap slowly could
result in personal injury.
Warning!
G
Overfilling of the fuel tank may create pres-
sure in the system which could cause a gas
discharge. This could cause the gas to spray
back out when removing the fuel pump noz-
zle, which could cause personal injury.!The fuel filler cap is tethered to the fuel
filler neck. Do not drop the cap. It could
damage the vehicle paint finish.
When refueling the vehicle, make cer-
tain that no gasoline comes into con-
tact with plastic tail lamp to prevent
damaging the lens.

225 Operation
At the gas station
Check regularly and before a long trip
1Coolant
2Brake fluid
Coolant
For normal replenishing, use water (pota-
ble water quality). For more information,
see “Coolant level” (
page 232) and see
“Fuels, coolants, lubricants, etc.”
(
page 333).Brake fluid
Windshield/rear window washer sys-
tem and headlamp cleaning system
For more information on refilling the reser-
voir, see “Windshield/rear window washer
system and headlamp cleaning system”
(
page 234).
iUse only premium unleaded gasoline
with a minimum Posted Octane Rating
of 91 (average of 96 RON / 86 MON).
Information on gasoline quality can
normally be found on the fuel pump.
More information on gasoline can be
found in the Factory Approved Service
Products pamphlet. iLeaving the engine running and the fuel
cap open can cause the ? malfunc-
tion indicator lamp to illuminate.
See also “Practical hints” section
(page 256).
iOpening the hood, see (
page 227).
!If you find that the brake fluid in the
brake fluid reservoir has fallen to the
minimum mark or below, have the
brake system checked for brake pad
thickness and leaks immediately. Noti-
fy an authorized Mercedes-Benz Light
Truck Center immediately. Do not add
brake fluid as this will not solve the
problem. For more information, see
“Practical hints” (
page 254) .

256 Practical hintsWhat to do if …Problem
Possible cause
Suggested solution
?
The yellow “CHECK ENGINE”
malfunction indicator lamp
comes on while driving.
There is a malfunction of:

The fuel management system


The ignition system


The emission control system


Systems which impact emissions
Such malfunctions may result in excessive
emissions values and may switch the engine
to its limp-home (emergency operation)
mode. Serious damage can occur to the
emission system.

Have the vehicle checked as soon as
possible by an authorized
Mercedes-Benz Light Truck Center.
An on-board diagnostic connector is
used by the service station to link the
vehicle to the shop diagnostics sys-
tem. It allows the accurate identifica-
tion of system malfunctions through
the readout of diagnostic trouble
codes. It is located near the hood lock
release on the upper left of footwell.
The fuel cap is not closed tightly.

Check the fuel cap.
Your gas tank is empty.

After refuelling, start the engine three
or four times in succession. The
limp-home mode is canceled.

258 Practical hintsWhat to do if …Problem
Possible cause
Suggested solution
<
The red seat belt non-usage
warning lamp illuminates briefly
after starting the engine.
The warning lamp reminds you to fasten seat
belts.

Fasten your seat belt.
The yellow fuel tank reserve warning lamp
illuminates while driving.
The fuel level has gone below the reserve
mark.

Refuel at the next gas station.

Also note the messages in the multi-
function display (
page 260).
The yellow fuel tank reserve warning lamp is
blinking.
The fuel cap is not closed tight.

Check the fuel cap.
1
The red SRS indicator lamp
comes on while driving.
There is a malfunction in the restraint sys-
tems. The airbags or emergency tensioning
device (ETD) could deploy unexpectedly or
fail to activate in an accident.

Drive with added caution to the near-
est authorized Mercedes-Benz Light
Truck Center.
Warning!
G
In the event a malfunction of the SRS is indi-
cated as outlined above, the SRS may not be
operational.
For your safety, we strongly recommend
that you visit an authorized Mercedes-Benz
Light Truck Center immediately to have the
system checked; otherwise the SRS may not
be activated when needed in an accident.
This could result in serious or fatal injury, or
it might deploy unexpectedly and unneces-
sarily which could also result in an accident
and/or injury to you or to others.

273 Practical hints
What to do if …
Display symbol
Display message
Possible cause
Possible solution
A
RESERVE FUEL
GO TO GAS STATION
The fuel level has dropped below the re-
serve mark.

Refuel at the next gas station
(page 224).
CHECK GAS CAP
SEE OPERATOR’S MANUAL
The fuel cap is not closed tightly.

Check the fuel cap (
page 224).
Y
HOOD OPEN!
You are driving with the hood open.

Close the hood (
page 228).
I
REMOVE KEY!
You have forgotten to remove the Smart-
Key.

Remove the SmartKey from the starter
switch.
REPLACE KEY
DRIVE TO WORKSHOP!
No additional code available for Smart-
Key.

Visit an authorized Mercedes-Benz
Light Truck Center.

333 Technical data
Fuels, coolants, lubricants, etc.
Fuels, coolants, lubricants, etc.
Capacities
Vehicle components and their respective
lubricants must match.Therefore use only brands tested and ap-
proved by Mercedes-Benz.Please refer to the Factory Approved Ser-
vice Products pamphlet, or inquire at your
Mercedes-Benz Light Truck Center.
Model
Capacity
Fuels, coolants, lubricants, etc.
Engine with oil filter
G500
G55AMG
8.5 US qt (8.0 l)
8.0 US qt (7.5 l)
Approved engine oils
Automatic transmission
9.0 US qt (8.5 l)
MB Automatic Transmission Oil
Transfer case
2.96 US qt (2.8 l)
MB part no. A 001 989 28 03 10
Differential lock mechanism
0.47 - 0.63 US qt
(0.45 - 0.6 l)
Brake fluid DOT 3+4, SAE J1703
Front axle
1.5 US qt (1.4 l)
Hypoid gear oil SAE 90, 85 W 90
Rear axle
1.9 US qt (1.8 l)
Hypoid gear oil SAE 90, 85 W 90
Power steering
approx. 1.06 US qt (1.0 l)
MB Power Steering Fluid, or
approved Dexron III ATF
Front wheel hubs
approx. 1.5 oz (43 g) each
High temperature roller bearing grease
Fuel tank
including a reserve of
25.4 US gal (96.0 l)
5.3 US gal (20.0 l)
Premium unleaded gasoline:
Posted Octane 91
(average of 96 RON / 86 MON)

334 Technical dataFuels, coolants, lubricants, etc.Engine oils
Engine oils are specifically tested for their
suitability in our engines. Therefore, use
only engine oils recommended by
Mercedes-Benz. Information on approved
engine oils is available in the Factory Ap-
proved Service Products pamphlet, or at
your authorized Mercedes-Benz Light
Truck Center.Please follow the FSS and Service Booklet
recommendations for scheduled oil chang-
es. Failure to do so could result in engine
damage not covered by the
Mercedes-Benz Limited Warranty.
Model
Capacity
Fuels, coolants, lubricants, etc.
Cooling system
approx. 12.7 US qt (12.0 l)
MB Anticorrosion/Antifreeze
Air conditioning system
R-134a refrigerant and
special PAG lubricant oil (never R-12)
Windshield/rear window washer system
and headlamp cleaning system
approx. 7.9 US qt (7.5 l)
MB Windshield Washer Concentrate
and water
1
1Use MB Windshield Washer Concentrate “S” and water for temperatures above freezing point or MB Windshield Washer Concentrate “S” and commercially available
premixed windshield washer solvent / antifreeze for temperatures below freezing point. Follow suggested mixing ratios (page 339).
!Always check the oil filler cap
(page 232) for important informa-
tion pertaining to the engine oil need-
ing to meet a specific Mercedes-Benz
specification (e.g. MB 229.5). If such
information is printed on the oil filler
cap, only use an engine oil from the list
of approved engine oils in the Factory
Approved Service Products pamphlet
that meets the specification indicated
on the oil filler cap.
Using engine oils of other specification
may cause the FSS to incorrectly deter-
mine the next service interval and will
result in engine damage not covered by
the Mercedes-Benz Limited Warranty.

337 Technical data
Fuels, coolants, lubricants, etc.
The coolant solution must be used year
round to provide the necessary corrosion
protection and increase in the boil-over
protection. Refer to Service Booklet for re-
placement interval.
To provide important corrosion protection,
the solution must be at least 45% anticor-
rosion/antifreeze (equivalent to freeze
protection to approx. - 22°F [-30°C]).
If you use a solution that is more than 55%
anticorrosion/antifreeze (freeze protec-
tion to approx. - 49°F [-45°C]), the engine
temperature will increase due to the lower
heat transfer capability of the solution.
Therefore, do not use more than this
amount of anticorrosion/antifreeze.If the coolant level is low, water and MB
anticorrosion /antifreeze should be used
to bring it up to the proper level (have cool-
ing system checked for signs of leakage).
Please make sure the mixture is in accor-
dance with label instructions.
The water in the cooling system must meet
minimum requirements, which are usually
satisfied by normal drinking water. If you
are not sure about the water quality, con-
sult your authorized Mercedes-Benz Light
Truck Center.
Anticorrosion/antifreeze
Your vehicle contains a number of alumi-
num parts. The use of aluminum compo-
nents in motor vehicle engines
necessitates that anticorrosion/antifreeze
coolant used in such engines be specifical-
ly formulated to protect the aluminum
parts. (Failure to use such anticorro-
sion/antifreeze coolant will result in a sig-
nificantly shortened service life.)
Therefore, the following product is strongly
recommended for use in your vehicle:
Mercedes-Benz anticorrosion/antifreeze
agent.