2008 SsangYong Rexton Y280 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Year: 2008 Chassis Code: Y280 Generation Generation Name: RX-2 (Second Generation) Generation Start Year: 2006 Generation End Year: 2012 Codes Engine Code Primary: G23D (Gasoline) Engine Code Secondary 1: G32D (Gasoline) Engine Code Secondary 2: D27DT (Diesel) 👋 Introduction Market Position Segment: Mid-size SUV Key Selling Points: Rugged styling, robust powertrain options, and off-road capability. Competitive Analysis Competitors: Hyundai Santa Fe, Kia Sorento, Mitsubishi Pajero Sport, Toyota Fortuner (depending on market). Key Features Manual Value Proposition: Inexpensive way to keep the vehicle working properly, provides step-by-step instructions with detailed diagrams for accurate and efficient repairs. 📋 Manual Details Coverage Areas Coverage Type: Complete Factory Service Repair Workshop Manual Vehicle Covered: 2008 SsangYong Rexton Y280 Page Count Estimated Page Count: High (estimated 1000+ pages based on typical comprehensive manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Compatibility: All Versions of Windows & Mac Download Availability: Instant Download Printability: All pages are printable Software Requirements: Adobe PDF Reader & WinZip 📖 Manual Coverage Systems Covered Engine Systems Gasoline: G23D (EU4), G32D (EU4) - General, Assembly, Fuel System, Intake System, Exhaust System, Lubrication System, Cooling System, Electric Devices, Control System Engine Systems Diesel: D27DT (EU4) - General, Assembly, Fuel System, Intake System, Exhaust System, Lubrication System, Cooling System, Electric Devices, Control System Electrical Systems: Electrical System, Fuses & Relays, STICS (likely related to immobilizer/security), Cluster, Lamps, Switches, Wiper/Washer System, Rain Sensor Unit, PAS (Power Assisted Steering), AV (Audio/Visual) Chassis Systems: Batra 4-speed Auto Transmission, DC 5-speed Auto Transmission, Manual Transmission, Clutch, Part-Time Transfer Case, Axle System, TOD (Torque on Demand), Propeller Shaft, Suspension System, Brakes System, ESP (Electronic Stability Program), ABS (Anti-lock Braking System), Power Steering System, Wheels & Tires, Special Service Tools Body Systems: Air Conditioning System, FATC (Fully Automatic Temperature Control), Heater Ventilation System, FFH System (likely Fuel Fired Heater), PTC System (Positive Temperature Coefficient heater), Airbag System, Body Interior, Body Exterior, Body Repair, Sunroof, Seats, Special Service Tools Diagnosis Systems: ECU (Gasoline & Diesel), Brake Diagnosis, Airbag Diagnosis, CCCS (likely related to emissions/cruise control), FATC, FFH, P/Trunk (Power Trunk), Rain Sensor, STICS, TC (Transfer Case), TCH (likely Transmission Control), TGS Lever (Transfer Gear Selector Lever) Electrical Wiring Diagrams: General Information, Connectors & Grounds, Power Distribution, Circuits Procedures Included General Procedures: General Vehicle Information, Troubleshooting, Diagnostics Engine Procedures: Complete disassembly and reassembly of engine components, fuel system servicing, intake/exhaust system repairs, lubrication system maintenance, cooling system repairs, electrical component troubleshooting, engine control system diagnostics. Transmission Procedures: Service and repair for 4-speed automatic, 5-speed automatic, and manual transmissions; clutch system repair; transfer case servicing. Chassis Procedures: Suspension system repair and alignment, brake system servicing (including ABS and ESP), power steering system maintenance, axle and driveshaft repair, wheel and tire servicing. Body Procedures: Air conditioning and climate control system servicing, interior trim removal and installation, exterior panel repair and adjustment, sunroof maintenance, seat removal and repair. Electrical Procedures: Wiring harness tracing, fuse and relay identification, component testing, troubleshooting of electrical systems including lighting, wipers, and sensors. Diagnostic Procedures: ECU diagnostics for both gasoline and diesel engines, brake system diagnostics, airbag system diagnostics, and specific system diagnostics as listed (FATC, FFH, Rain Sensor, etc.). Technical Depth Depth Of Coverage: Comprehensive; covers complete disassembly and reassembly of the machine, step-by-step instructions, and detailed exploded pictures/diagrams. User Focus: Suitable for both do-it-yourselfers and experienced mechanics. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: Top quality diagrams and easy-to-read text sections Binding Type Type: Digital (Downloadable PDF) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Model: G23D Type: Inline 4-cylinder Gasoline Displacement: Approximately 2.3 Liters Fuel System: Multi-point Fuel Injection (MPI) Emission Standard: EU4 compliant Secondary Engine 1 Model: G32D Type: V6 Gasoline Displacement: Approximately 3.2 Liters Fuel System: Multi-point Fuel Injection (MPI) Emission Standard: EU4 compliant Secondary Engine 2 Model: D27DT Type: Inline 5-cylinder Diesel (Turbodiesel) Displacement: Approximately 2.7 Liters Fuel System: Common Rail Direct Injection (CRDi) Emission Standard: EU4 compliant Performance Horsepower G23D: Estimated 150-160 HP (exact figures vary by market and tune) Torque G23D: Estimated 210-230 Nm (exact figures vary by market and tune) Horsepower G32D: Estimated 170-180 HP (exact figures vary by market and tune) Torque G32D: Estimated 240-260 Nm (exact figures vary by market and tune) Horsepower D27Dt: Estimated 165-175 HP (exact figures vary by market and tune) Torque D27Dt: Estimated 340-360 Nm (exact figures vary by market and tune) 🔧 Transmission Standard Type: Dependent on engine and trim level (likely 5-speed Manual or 4-speed Automatic for lower trims, potentially 5-speed Automatic for higher trims/engines) Optional Type: Batra 4-speed Automatic Transmission, DC 5-speed Automatic Transmission Features Drivetrain: Part-time 4WD with TOD (Torque on Demand) system, offering selectable 2WD/4WD modes. Transfer Case: Part-time Transfer Case 📐 Dimensions Exterior Length: Approx. 4,755 mm (187.2 in)...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton

Year:

Chassis Code:

Generation

Generation Name:

RX-2 (Second Generation)

Generation Start Year:

Generation End Year:

Codes

Engine Code Primary:

G23D (Gasoline)

Engine Code Secondary 1:

G32D (Gasoline)

Engine Code Secondary 2:

D27DT (Diesel)

👋 Introduction

Market Position

Segment:

Mid-size SUV

Key Selling Points:

Rugged styling, robust powertrain options, and off-road capability.

Competitive Analysis

Competitors:

Hyundai Santa Fe, Kia Sorento, Mitsubishi Pajero Sport, Toyota Fortuner (depending on market).

Key Features

Manual Value Proposition:

Inexpensive way to keep the vehicle working properly, provides step-by-step instructions with detailed diagrams for accurate and efficient repairs.

📋 Manual Details

Coverage Areas

Coverage Type:

Complete Factory Service Repair Workshop Manual

Vehicle Covered:

2008 SsangYong Rexton Y280

Page Count

Estimated Page Count:

High (estimated 1000+ pages based on typical comprehensive manuals)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Compatibility:

All Versions of Windows & Mac

Download Availability:

Instant Download

Printability:

All pages are printable

Software Requirements:

Adobe PDF Reader & WinZip

📖 Manual Coverage

Systems Covered

Engine Systems Gasoline:

G23D (EU4), G32D (EU4) - General, Assembly, Fuel System, Intake System, Exhaust System, Lubrication System, Cooling System, Electric Devices, Control System

Engine Systems Diesel:

D27DT (EU4) - General, Assembly, Fuel System, Intake System, Exhaust System, Lubrication System, Cooling System, Electric Devices, Control System

Electrical Systems:

Electrical System, Fuses & Relays, STICS (likely related to immobilizer/security), Cluster, Lamps, Switches, Wiper/Washer System, Rain Sensor Unit, PAS (Power Assisted Steering), AV (Audio/Visual)

Chassis Systems:

Batra 4-speed Auto Transmission, DC 5-speed Auto Transmission, Manual Transmission, Clutch, Part-Time Transfer Case, Axle System, TOD (Torque on Demand), Propeller Shaft, Suspension System, Brakes System, ESP (Electronic Stability Program), ABS (Anti-lock Braking System), Power Steering System, Wheels & Tires, Special Service Tools

Body Systems:

Air Conditioning System, FATC (Fully Automatic Temperature Control), Heater Ventilation System, FFH System (likely Fuel Fired Heater), PTC System (Positive Temperature Coefficient heater), Airbag System, Body Interior, Body Exterior, Body Repair, Sunroof, Seats, Special Service Tools

Diagnosis Systems:

ECU (Gasoline & Diesel), Brake Diagnosis, Airbag Diagnosis, CCCS (likely related to emissions/cruise control), FATC, FFH, P/Trunk (Power Trunk), Rain Sensor, STICS, TC (Transfer Case), TCH (likely Transmission Control), TGS Lever (Transfer Gear Selector Lever)

Electrical Wiring Diagrams:

General Information, Connectors & Grounds, Power Distribution, Circuits

Procedures Included

General Procedures:

General Vehicle Information, Troubleshooting, Diagnostics

Engine Procedures:

Complete disassembly and reassembly of engine components, fuel system servicing, intake/exhaust system repairs, lubrication system maintenance, cooling system repairs, electrical component troubleshooting, engine control system diagnostics.

Transmission Procedures:

Service and repair for 4-speed automatic, 5-speed automatic, and manual transmissions; clutch system repair; transfer case servicing.

Chassis Procedures:

Suspension system repair and alignment, brake system servicing (including ABS and ESP), power steering system maintenance, axle and driveshaft repair, wheel and tire servicing.

Body Procedures:

Air conditioning and climate control system servicing, interior trim removal and installation, exterior panel repair and adjustment, sunroof maintenance, seat removal and repair.

Electrical Procedures:

Wiring harness tracing, fuse and relay identification, component testing, troubleshooting of electrical systems including lighting, wipers, and sensors.

Diagnostic Procedures:

ECU diagnostics for both gasoline and diesel engines, brake system diagnostics, airbag system diagnostics, and specific system diagnostics as listed (FATC, FFH, Rain Sensor, etc.).

Technical Depth

Depth Of Coverage:

Comprehensive; covers complete disassembly and reassembly of the machine, step-by-step instructions, and detailed exploded pictures/diagrams.

User Focus:

Suitable for both do-it-yourselfers and experienced mechanics.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Top quality diagrams and easy-to-read text sections

Binding Type

Type:

Digital (Downloadable PDF)

Paper Type

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Model:

Type:

Inline 4-cylinder Gasoline

Displacement:

Approximately 2.3 Liters

Fuel System:

Multi-point Fuel Injection (MPI)

Emission Standard:

EU4 compliant

Secondary Engine 1

Model:

Type:

V6 Gasoline

Displacement:

Approximately 3.2 Liters

Fuel System:

Multi-point Fuel Injection (MPI)

Emission Standard:

EU4 compliant

Secondary Engine 2

Model:

D27DT

Type:

Inline 5-cylinder Diesel (Turbodiesel)

Displacement:

Approximately 2.7 Liters

Fuel System:

Common Rail Direct Injection (CRDi)

Emission Standard:

EU4 compliant

Performance

Horsepower G23D:

Estimated 150-160 HP (exact figures vary by market and tune)

Torque G23D:

Estimated 210-230 Nm (exact figures vary by market and tune)

Horsepower G32D:

Estimated 170-180 HP (exact figures vary by market and tune)

Torque G32D:

Estimated 240-260 Nm (exact figures vary by market and tune)

Horsepower D27Dt:

Estimated 165-175 HP (exact figures vary by market and tune)

Torque D27Dt:

Estimated 340-360 Nm (exact figures vary by market and tune)

🔧 Transmission

Standard

Type:

Dependent on engine and trim level (likely 5-speed Manual or 4-speed Automatic for lower trims, potentially 5-speed Automatic for higher trims/engines)

Optional

Type:

Batra 4-speed Automatic Transmission, DC 5-speed Automatic Transmission

Features

Drivetrain:

Part-time 4WD with TOD (Torque on Demand) system, offering selectable 2WD/4WD modes.

Transfer Case:

Part-time Transfer Case

📐 Dimensions

Exterior

Length:

Approx. 4,755 mm (187.2 in)

Width:

Approx. 1,865 mm (73.4 in)

Height:

Approx. 1,760 mm (69.3 in)

Wheelbase:

Approx. 2,760 mm (108.7 in)

Weights

Curb Weight:

Varies by engine and configuration, typically 1,900 - 2,200 kg (4,189 - 4,850 lbs)

Gross Vehicle Weight Rating:

Varies, typically around 2,800 - 3,000 kg (6,173 - 6,614 lbs)

🛡️ Safety Features

Ratings

Crash Test Data:

Information likely varies by market and specific testing body (e.g., Euro NCAP). Specific ratings for this model year are not universally published.

Active Features

Braking Systems:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)

Stability Control:

ESP (Electronic Stability Program)

Traction Control:

TCS (Traction Control System)

Passive Features

Airbags:

Front airbags for driver and passenger, side airbags and curtain airbags may be optional or standard depending on trim level.

Seat Belts:

3-point seat belts with pretensioners and force limiters

💡 Technology Features

Infotainment

System Features:

Basic infotainment systems for the era, likely including an AM/FM radio, CD player, and possibly an auxiliary input. Navigation systems were likely optional or aftermarket.

Driver Assistance

Features:

ABS, ESP, Traction Control System (TCS), parking sensors (potentially rear), cruise control.

Connectivity

Features:

Limited by the era; no advanced smartphone integration like Apple CarPlay or Android Auto. Bluetooth connectivity for hands-free calling might have been available on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or 6-12 months, whichever comes first. Refer to manual for exact specification based on driving conditions.

Oil Change Diesel:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Diesel engines may have shorter intervals. Refer to manual for exact specification.

Air Filter Replacement:

Recommended every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on operating environment.

Fuel Filter Replacement Diesel:

Crucial for diesel engines; often recommended every 20,000 - 40,000 miles (32,000 - 64,000 km).

Fluid Specifications

Engine Oil G23D G32D:

API SN or higher, SAE 5W-30 or 5W-40 (check manual for specific viscosity and API rating).

Engine Oil D27Dt:

API CJ-4 or higher, SAE 5W-30 or 5W-40 (check manual for specific viscosity and API rating).

Coolant:

Ethylene Glycol based coolant with corrosion inhibitors (e.g., Asian Blue or equivalent). Check manual for specific type and capacity.

Transmission Fluid Auto:

Dexron III or equivalent Automatic Transmission Fluid (ATF). Check manual for specific type and capacity.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, viscosity dependent on climate. Check manual for specific type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Diesel Engine:

Potential for issues with fuel injectors, glow plugs, and EGR systems on the D27DT. Turbocharger health is critical. Water ingress into the fuel system can cause significant damage.

Transmission:

Early automatic transmissions can exhibit shifting issues or premature wear. Regular fluid changes are crucial.

Electrical:

Corrosion on electrical connectors, particularly in humid or coastal environments, can lead to intermittent faults. Battery health and charging system are important.

Suspension Chassis:

Wear in suspension bushings and ball joints can occur with mileage and off-road use. Rust on chassis components may be a concern in certain climates.

📚 Vehicle History

Brand Heritage

Ssangyong Legacy:

SsangYong Motor Company, a South Korean manufacturer with a history of producing rugged, off-road capable vehicles, often utilizing diesel engines and licensed Mercedes-Benz technology.

Model Evolution

Rexton Lineage:

The Rexton is SsangYong's flagship SUV, first introduced in 2001. The 2008 model represents the second generation (RX-2), which received styling updates and mechanical revisions over the original.

Production

Manufacturing Location:

South Korea

🏆 Awards & Recognition

Recognitions

Vehicle Awards:

The SsangYong Rexton has not received widespread major international awards. Its market appeal is more focused on value and capability rather than luxury or accolades.