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SsangYong Rexton (2001 to 2006) Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Generation: First Generation (RJ) Codes Model Code: RJ 👋 Introduction Market Position Vehicle Segment: Body-on-frame SUV, often competing in the mid-size to large SUV segment. Target Audience: Individuals and families seeking a robust, capable SUV with off-road prowess and towing capacity. Competitive Analysis Key Competitors: Likely competitors during its production run include models like the Toyota Land Cruiser Prado, Mitsubishi Pajero (Montero), Ford Everest, and Land Rover Discovery. Key Features Body On Frame Construction: Provides robust off-road capability and towing strength, characteristic of traditional SUVs. Four Wheel Drive Standard: Emphasis on all-weather and off-road performance. Engine Options: Variety of diesel and gasoline engines to suit different performance and economic needs. 📋 Manual Details Coverage Areas Applicable Years: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Page Count: 1991 Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, including cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system. Engine Management: Fuel injection system, ignition system, emission control systems, engine control unit (ECU) diagnostics and calibration. Transmission Manual: Manual gearbox overhaul, clutch system, shift mechanisms. Transmission Automatic: Automatic transmission overhaul, torque converter, valve body, electronic controls, fluid management. Drivetrain 4Wd: Four-wheel drive system operation, transfer case, differentials (front and rear), driveshafts, CV joints. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment specifications. Steering: Power steering system, steering rack/box, tie rods, steering column, steering angle sensor. Brakes: Hydraulic brake system, ABS, EBD, brake discs, pads, calipers, brake lines, parking brake system. Electrical System: Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams. Body And Interior: Body panel removal and installation, door mechanisms, interior trim, seats, HVAC system components, body sealing. Climate Control: Air conditioning system, heating system, blower motor, refrigerant types and capacities, system diagnosis. Procedures Included Scheduled Maintenance: Detailed maintenance schedules, oil change procedures, filter replacements, fluid level checks, lubrication points. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, fault codes, symptom-based troubleshooting guides. Repair Procedures: Step-by-step repair instructions for all major components and systems, including disassembly, reassembly, and adjustments. Diagnostics: OBD-II diagnostics, sensor testing, actuator testing, ECU function testing. Technical Data Specifications: Torque specifications for all fasteners, fluid capacities, clearances, electrical resistance values, battery specifications. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds. Visual Aids: Abundant high-quality pictures and detailed diagrams illustrating procedures and component locations. Part Diagrams: Illustrated parts diagrams for easy identification of components when ordering parts. 📊 Manual Specifications File Format File Format: Adobe PDF Searchability: Text-searchable PDF for quick information retrieval. Print Quality Printability: Fully printable pages, allowing users to print specific sections as needed. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Description: 2.7L Common Rail Diesel (OM662LA based) Engine 1 Power: 121 kW (162 hp) Engine 1 Torque: 342 N·m (252 lb·ft) Other Engines Engine 2 Description: 2.9L Diesel (Naturally Aspirated) Engine 3 Description: 3.2L Petrol (M162) Engine 3 Power: 162 kW (217 hp) Engine 3 Torque: 310 N·m (229 lb·ft) Fuel System Diesel Fuel System: Common Rail Direct Injection (for 2.7L variant) Petrol Fuel System: Multi-point Fuel Injection (MPI) 🔧 Transmission Standard Standard Transmission: Likely a 5-speed manual or 4-speed automatic transmission, depending on engine and trim. Optional Optional Transmission: A 4-speed automatic transmission was commonly available, especially with the more powerful engines. Features Transfer Case: Part-time 4WD system with low-range gearing (transfer case), offering selectable 2WD and 4WD modes. 📐 Dimensions Exterior Body Style: 5-door SUV Wheelbase: Approximately 2,830 mm (111.4 inches) Length: Approximately 4,710 mm (185.4 inches) Width: Approximately 1,865 mm (73.4 inches) Height: Approximately 1,775 mm (69.9 inches) Weights Curb Weight: Varies by engine and configuration, likely in the range of 1,900 - 2,100 kg (4,189 - 4,630 lbs). 🛡️ Safety Features Ratings Crash Test Data: Specific crash test ratings for this generation may be limited or vary by region. Generally built with robust construction principles. Active Features ABS: Anti-lock Braking System (ABS) typically standard. Ebd: Electronic Brakeforce Distribution (EBD) likely integrated with ABS. Passive Features Airbags: Front airbags for driver and passenger were common. Side airbags may have been optional on higher trims. Seatbelts: Three-point seatbelts with pretensioners, typically for front occupants. Body Structure: Reinforced body structure designed for SUV applications. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player. Cassette player may have been present on early models. Speaker configurations typically 4-8 speakers. Navigation: Optional navigation system available on higher trim levels, often integrated into the dashboard. Driver Assistance Cruise Control: Standard or optional cruise control. Parking Sensors: Rear parking sensors might have been available on later models or as an option. 🔧...
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SsangYong Rexton (2001 to 2006) Service Repair Manual
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Rexton
Generation:
First Generation (RJ)
Codes
Model Code:
RJ
👋 Introduction
Market Position
Vehicle Segment:
Body-on-frame SUV, often competing in the mid-size to large SUV segment.
Target Audience:
Individuals and families seeking a robust, capable SUV with off-road prowess and towing capacity.
Competitive Analysis
Key Competitors:
Likely competitors during its production run include models like the Toyota Land Cruiser Prado, Mitsubishi Pajero (Montero), Ford Everest, and Land Rover Discovery.
Key Features
Body On Frame Construction:
Provides robust off-road capability and towing strength, characteristic of traditional SUVs.
Four Wheel Drive Standard:
Emphasis on all-weather and off-road performance.
Engine Options:
Variety of diesel and gasoline engines to suit different performance and economic needs.
📋 Manual Details
Coverage Areas
Applicable Years:
2001, 2002, 2003, 2004, 2005, 2006
Page Count
Page Count:
1991
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, including cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system.
Engine Management:
Fuel injection system, ignition system, emission control systems, engine control unit (ECU) diagnostics and calibration.
Transmission Manual:
Manual gearbox overhaul, clutch system, shift mechanisms.
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, electronic controls, fluid management.
Drivetrain 4Wd:
Four-wheel drive system operation, transfer case, differentials (front and rear), driveshafts, CV joints.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment specifications.
Steering:
Power steering system, steering rack/box, tie rods, steering column, steering angle sensor.
Brakes:
Hydraulic brake system, ABS, EBD, brake discs, pads, calipers, brake lines, parking brake system.
Electrical System:
Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams.
Body And Interior:
Body panel removal and installation, door mechanisms, interior trim, seats, HVAC system components, body sealing.
Climate Control:
Air conditioning system, heating system, blower motor, refrigerant types and capacities, system diagnosis.
Procedures Included
Scheduled Maintenance:
Detailed maintenance schedules, oil change procedures, filter replacements, fluid level checks, lubrication points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault codes, symptom-based troubleshooting guides.
Repair Procedures:
Step-by-step repair instructions for all major components and systems, including disassembly, reassembly, and adjustments.
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, ECU function testing.
Technical Data Specifications:
Torque specifications for all fasteners, fluid capacities, clearances, electrical resistance values, battery specifications.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds.
Visual Aids:
Abundant high-quality pictures and detailed diagrams illustrating procedures and component locations.
Part Diagrams:
Illustrated parts diagrams for easy identification of components when ordering parts.
📊 Manual Specifications
File Format
File Format:
Adobe PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality
Printability:
Fully printable pages, allowing users to print specific sections as needed.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1 Description:
2.7L Common Rail Diesel (OM662LA based)
Engine 1 Power:
121 kW (162 hp)
Engine 1 Torque:
342 N·m (252 lb·ft)
Other Engines
Engine 2 Description:
2.9L Diesel (Naturally Aspirated)
Engine 3 Description:
3.2L Petrol (M162)
Engine 3 Power:
162 kW (217 hp)
Engine 3 Torque:
310 N·m (229 lb·ft)
Fuel System
Diesel Fuel System:
Common Rail Direct Injection (for 2.7L variant)
Petrol Fuel System:
Multi-point Fuel Injection (MPI)
🔧 Transmission
Standard
Standard Transmission:
Likely a 5-speed manual or 4-speed automatic transmission, depending on engine and trim.
Optional
Optional Transmission:
A 4-speed automatic transmission was commonly available, especially with the more powerful engines.
Features
Transfer Case:
Part-time 4WD system with low-range gearing (transfer case), offering selectable 2WD and 4WD modes.
📐 Dimensions
Exterior
Body Style:
5-door SUV
Wheelbase:
Approximately 2,830 mm (111.4 inches)
Length:
Approximately 4,710 mm (185.4 inches)
Width:
Approximately 1,865 mm (73.4 inches)
Height:
Approximately 1,775 mm (69.9 inches)
Weights
Curb Weight:
Varies by engine and configuration, likely in the range of 1,900 - 2,100 kg (4,189 - 4,630 lbs).
🛡️ Safety Features
Ratings
Crash Test Data:
Specific crash test ratings for this generation may be limited or vary by region. Generally built with robust construction principles.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard.
Ebd:
Electronic Brakeforce Distribution (EBD) likely integrated with ABS.
Passive Features
Airbags:
Front airbags for driver and passenger were common. Side airbags may have been optional on higher trims.
Seatbelts:
Three-point seatbelts with pretensioners, typically for front occupants.
Body Structure:
Reinforced body structure designed for SUV applications.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player. Cassette player may have been present on early models. Speaker configurations typically 4-8 speakers.
Navigation:
Optional navigation system available on higher trim levels, often integrated into the dashboard.
Driver Assistance
Cruise Control:
Standard or optional cruise control.
Parking Sensors:
Rear parking sensors might have been available on later models or as an option.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals, typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type used.
Transmission Fluid Change:
Refer to manual. Automatic transmission fluid typically requires changing every 40,000-80,000 km (25,000-50,000 miles).
Coolant Change:
Refer to manual, typically every 2-4 years or 40,000-80,000 km (25,000-50,000 miles).
Fluid Specifications
Engine Oil Specification:
Refer to manual for exact specification (e.g., API CF or CH-4 for diesel, SG/SH for petrol), viscosity grade typically 10W-40 or 15W-40 for diesel, 5W-30 or 10W-40 for petrol.
Automatic Transmission Fluid:
Refer to manual for specific type (e.g., Dexron II/III or equivalent).
Brake Fluid Specification:
DOT 3 or DOT 4.
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors.
Known Issues
Common Problems:
Potential issues may include diesel injector problems (especially on older common rail systems), EGR valve issues on diesel engines, early transmission shift quality issues, and suspension component wear. Electrical gremlins can also occur in older vehicles.
📚 Vehicle History
Brand Heritage
Ssangyong Legacy:
SsangYong, a South Korean manufacturer, has a history dating back to 1954, with a focus on SUVs and commercial vehicles. They have a reputation for robust, truck-like engineering.
Model Evolution
Rexton Development:
The Rexton (RJ) was SsangYong's flagship SUV, developed to compete in the global SUV market. It was designed to offer a blend of luxury, utility, and off-road capability, often leveraging Mercedes-Benz technology in its early development stages.
Production
Production Period:
2001-2006
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
Specific industry awards for this generation are not widely publicized, but SsangYong vehicles are generally recognized for their ruggedness and value proposition in their respective segments.
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