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SsangYong Kyron 2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Kyron Year: 2005 Body Style: SUV (Sport Utility Vehicle) Generation Generation Name: First Generation Generation Years: 2005-2011 Codes Chassis Code: P100 👋 Introduction Market Position Segment: Mid-size SUV, often positioned as an affordable yet capable option Target Audience: Individuals and families seeking a rugged, versatile SUV with off-road capability at a competitive price point. Competitive Analysis Competitors 2005: Hyundai Santa Fe, Kia Sorento, Mitsubishi Outlander, Ford Escape, Nissan Xterra Key Features Platform: Body-on-frame construction, shared platform with some Mercedes-Benz models of the era (via Daewoo/GM ownership of SsangYong). Powertrain Options: Known for robust diesel engines, often featuring selectable 4WD or full-time 4WD. Design Language: Distinctive styling, often characterized by a muscular stance and prominent grille. 📋 Manual Details Coverage Areas Coverage Type: Full Service and Repair Specific Coverage: All mechanical, electrical, and body components Page Count Estimated Page Count: 1000+ Manual Type Type: Professional Technical Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, lubrication, cooling, fuel, ignition, exhaust, timing, emissions Engine Management: ECU operation, sensors, actuators, diagnostic trouble codes (DTCs), wiring diagrams Transmission Manual: Gearbox overhaul, clutch system, shift mechanisms Transmission Automatic: Automatic transmission overhaul, torque converter, valve body, electronic control Drivetrain: Driveshafts, differentials, transfer case, AWD system (if applicable) Suspension: Front and rear suspension components, shock absorbers, springs, control arms, alignment Steering: Steering column, steering gear, power steering system, wheel alignment Brakes: Brake system diagnostics, hydraulic components, ABS, EBD, parking brake Electrical System: Battery, charging system, starting system, lighting, instrumentation, wiring harnesses Body And Chassis: Body panel repair, door mechanisms, interior trim, chassis frame, rustproofing HVAC: Heating, ventilation, and air conditioning system components, refrigerant, diagnostics Interior And Exterior: Seats, dashboard, panels, exterior trim, glass, mirrors Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic flowcharts, common fault finding, symptom analysis Repair: Component replacement, sub-assembly repair, detailed disassembly and reassembly Diagnostics: OBD-II scanning, sensor testing, actuator testing, electrical circuit analysis Specifications: Torque specifications, clearances, tolerances, pressures, voltages Special Tools: Identification and usage of specialized tools required for repairs Technical Depth Depth: Comprehensive (from basic maintenance to full rebuilds and diagnostics) 📊 Manual Specifications File Format Format: PDF Searchable: Yes (assumed for professional PDF) Print Quality Printability: Full Printable Zoom Capability: Yes Binding Type Binding: Digital (Downloadable) Paper Type Paper Format For Printing: Standard paper sizes (A4/Letter) Requirements Software Requirements: Adobe PDF Reader, WinZip (for potential archives) Compatibility: All versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: XDi200 (Diesel) Engine Type: Inline-4 Turbocharged Diesel Displacement: 1998 cc Bore X Stroke: 84.7 mm x 90.0 mm Compression Ratio: 18.6:1 Horsepower Ps: 118 PS @ 4000 rpm Torque Nm: 240 Nm @ 1800-3000 rpm Engine Alternatives Engine Type 2: XDi270 (Diesel) Displacement 2: 2696 cc Horsepower Ps 2: 120 PS @ 3800 rpm (XDi270 LE), 141 PS @ 3800 rpm (XDi270 XVT) Torque Nm 2: 250 Nm @ 1800-3000 rpm (XDi270 LE), 340 Nm @ 1800-2800 rpm (XDi270 XVT) Fuel System Injection Type: Common Rail Direct Injection (CRDI) Fuel Type: Diesel 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Optional Transmission Type Opt: 5-speed Automatic (T-Tronic) Features Drivetrain Options: RWD (Rear-Wheel Drive), 4WD (Part-time or Full-time) 📐 Dimensions Exterior Length: 4650 mm Width: 1865 mm Height: 1735 mm Wheelbase: 2740 mm Weights Curb Weight Kg: 1920 - 2050 kg (approximate, depending on engine and drivetrain) Gross Vehicle Weight Rating Kg: 2610 kg (approximate) 🛡️ Safety Features Ratings Crash Test Ratings: Variable by region; generally mixed to moderate ratings in independent tests of the era. Active Features ABS: Standard on most models Ebd: Electronic Brake-force Distribution (often paired with ABS) Traction Control: Available on some higher trims or 4WD models Passive Features Airbags: Front airbags standard, side airbags available on higher trims โครงสร้าง ตัวถัง: Reinforced chassis with crumple zones 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, often with optional amplifier and subwoofer. Basic speaker configurations. Navigation: Optional aftermarket or dealer-installed navigation systems available. Driver Assistance Cruise Control: Available on higher trim levels. Parking Sensors: Available as an option or aftermarket fitment. Connectivity Bluetooth: Rarely factory-equipped on 2005 models; typically requires aftermarket installation. Usb Aux: Not standard on most 2005 models; often available via aftermarket adapter for the audio system. 🔧 Maintenance Service Intervals Oil Change Diesel: Every 7,500 - 10,000 km or 6-12 months (whichever comes first), depending on driving conditions. Air Filter Replacement Diesel: Every 20,000 - 30,000 km or as needed based on air quality. Fuel Filter Replacement Diesel: Every 40,000 - 60,000 km. Timing Belt Replacement Diesel: 100,000 - 150,000 km (if applicable; some models may use timing chains). Consult manual for specific engine. Fluid Specifications Engine Oil Diesel: API CF-4 or CG-4, SAE 10W-30 or 15W-40 (confirm with manual based on...
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SsangYong Kyron 2005 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Kyron
Year:
2005
Body Style:
SUV (Sport Utility Vehicle)
Generation
Generation Name:
First Generation
Generation Years:
2005-2011
Codes
Chassis Code:
P100
👋 Introduction
Market Position
Segment:
Mid-size SUV, often positioned as an affordable yet capable option
Target Audience:
Individuals and families seeking a rugged, versatile SUV with off-road capability at a competitive price point.
Competitive Analysis
Competitors 2005:
Hyundai Santa Fe, Kia Sorento, Mitsubishi Outlander, Ford Escape, Nissan Xterra
Key Features
Platform:
Body-on-frame construction, shared platform with some Mercedes-Benz models of the era (via Daewoo/GM ownership of SsangYong).
Powertrain Options:
Known for robust diesel engines, often featuring selectable 4WD or full-time 4WD.
Design Language:
Distinctive styling, often characterized by a muscular stance and prominent grille.
📋 Manual Details
Coverage Areas
Coverage Type:
Full Service and Repair
Specific Coverage:
All mechanical, electrical, and body components
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Professional Technical Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, lubrication, cooling, fuel, ignition, exhaust, timing, emissions
Engine Management:
ECU operation, sensors, actuators, diagnostic trouble codes (DTCs), wiring diagrams
Transmission Manual:
Gearbox overhaul, clutch system, shift mechanisms
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, electronic control
Drivetrain:
Driveshafts, differentials, transfer case, AWD system (if applicable)
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, alignment
Steering:
Steering column, steering gear, power steering system, wheel alignment
Brakes:
Brake system diagnostics, hydraulic components, ABS, EBD, parking brake
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, wiring harnesses
Body And Chassis:
Body panel repair, door mechanisms, interior trim, chassis frame, rustproofing
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant, diagnostics
Interior And Exterior:
Seats, dashboard, panels, exterior trim, glass, mirrors
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Troubleshooting:
Diagnostic flowcharts, common fault finding, symptom analysis
Repair:
Component replacement, sub-assembly repair, detailed disassembly and reassembly
Diagnostics:
OBD-II scanning, sensor testing, actuator testing, electrical circuit analysis
Specifications:
Torque specifications, clearances, tolerances, pressures, voltages
Special Tools:
Identification and usage of specialized tools required for repairs
Technical Depth
Depth:
Comprehensive (from basic maintenance to full rebuilds and diagnostics)
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (assumed for professional PDF)
Print Quality
Printability:
Full Printable
Zoom Capability:
Yes
Binding Type
Binding:
Digital (Downloadable)
Paper Type
Paper Format For Printing:
Standard paper sizes (A4/Letter)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for potential archives)
Compatibility:
All versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
XDi200 (Diesel)
Engine Type:
Inline-4 Turbocharged Diesel
Displacement:
1998 cc
Bore X Stroke:
84.7 mm x 90.0 mm
Compression Ratio:
18.6:1
Horsepower Ps:
118 PS @ 4000 rpm
Torque Nm:
240 Nm @ 1800-3000 rpm
Engine Alternatives
Engine Type 2:
XDi270 (Diesel)
Displacement 2:
2696 cc
Horsepower Ps 2:
120 PS @ 3800 rpm (XDi270 LE), 141 PS @ 3800 rpm (XDi270 XVT)
Torque Nm 2:
250 Nm @ 1800-3000 rpm (XDi270 LE), 340 Nm @ 1800-2800 rpm (XDi270 XVT)
Fuel System
Injection Type:
Common Rail Direct Injection (CRDI)
Fuel Type:
Diesel
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual
Optional
Transmission Type Opt:
5-speed Automatic (T-Tronic)
Features
Drivetrain Options:
RWD (Rear-Wheel Drive), 4WD (Part-time or Full-time)
📐 Dimensions
Exterior
Length:
4650 mm
Width:
1865 mm
Height:
1735 mm
Wheelbase:
2740 mm
Weights
Curb Weight Kg:
1920 - 2050 kg (approximate, depending on engine and drivetrain)
Gross Vehicle Weight Rating Kg:
2610 kg (approximate)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Variable by region; generally mixed to moderate ratings in independent tests of the era.
Active Features
ABS:
Standard on most models
Ebd:
Electronic Brake-force Distribution (often paired with ABS)
Traction Control:
Available on some higher trims or 4WD models
Passive Features
Airbags:
Front airbags standard, side airbags available on higher trims
โครงสร้าง ตัวถัง:
Reinforced chassis with crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, often with optional amplifier and subwoofer. Basic speaker configurations.
Navigation:
Optional aftermarket or dealer-installed navigation systems available.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Available as an option or aftermarket fitment.
Connectivity
Bluetooth:
Rarely factory-equipped on 2005 models; typically requires aftermarket installation.
Usb Aux:
Not standard on most 2005 models; often available via aftermarket adapter for the audio system.
🔧 Maintenance
Service Intervals
Oil Change Diesel:
Every 7,500 - 10,000 km or 6-12 months (whichever comes first), depending on driving conditions.
Air Filter Replacement Diesel:
Every 20,000 - 30,000 km or as needed based on air quality.
Fuel Filter Replacement Diesel:
Every 40,000 - 60,000 km.
Timing Belt Replacement Diesel:
100,000 - 150,000 km (if applicable; some models may use timing chains). Consult manual for specific engine.
Fluid Specifications
Engine Oil Diesel:
API CF-4 or CG-4, SAE 10W-30 or 15W-40 (confirm with manual based on climate and specific engine variant).
Coolant:
Ethylene Glycol based coolant, meeting JASO M325 or equivalent. 50/50 mix with distilled water.
Transmission Fluid Manual:
GL-4 SAE 75W-90 Gear Oil
Transmission Fluid Automatic:
Dexron III-H or equivalent (confirm with manual).
Brake Fluid:
DOT 3 or DOT 4 (confirm with manual)
Known Issues
Common Complaints:
Turbocharger issues (especially on early models), EGR valve clogging, glow plug reliability, suspension component wear (bushings, ball joints), minor electrical gremlins.
Diesel Specific Concerns:
Potential for injector issues if fuel quality is poor, particulate filter (DPF) clogging if not driven appropriately for regeneration.
📚 Vehicle History
Brand Heritage
Brand Origin:
South Korea, originally established as Dongbang Motor Co., Ltd. in 1954. Rebranded as SsangYong Motor Company in 1986.
Key Association:
SsangYong has had periods of ownership by various international groups, including KG Mobility (formerly Daewoo Motor Company/General Motors).
Model Evolution
Kyron Introduction:
Launched in 2005 as a successor to the SsangYong Rexton I (though the Rexton II was introduced shortly after). Designed by Ken Greenley.
Design Influence:
The Kyron's design was influenced by the SsangYong WZ concept car. Shared its platform with the SsangYong Musso.
Production
Manufacturing Location:
Pyeongtaek, South Korea
Production Years:
2005 – 2011 (First Generation)
🏆 Awards & Recognition
Recognitions
Awards Achievements:
While not a multiple award winner, the Kyron aimed to provide a competitive package of utility, capability, and value, often recognized in its domestic market for these attributes.
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