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Ssangyong Rexton I & II EWD LHD Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Generation: I & II Chassis Code: G200 (Rexton I), G200/G200W (Rexton II) Body Style: SUV Drive Type: EWD (Electronic 4WD) Steering Side: LHD (Left-Hand Drive) 👋 Introduction Market Position Target Audience: Technicians, mechanics, DIY enthusiasts, and anyone wanting to repair or learn about the SsangYong Rexton. Value Proposition: Provides comprehensive factory-level information at a competitive price for efficient vehicle repair and maintenance. Competitive Analysis Alternative Resources: Highlights the inconvenience and cost of searching through numerous physical bookstores for repair information. Key Features Completeness: Official full complete factory service repair manual. Accessibility: Instant download provides immediate access to crucial repair data. User Support: Customer support available for concerns or download issues. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Page Count Estimate: Hundreds to Thousands Delivery Method: Instant Download Software Requirements: Adobe PDF Reader, WinZip (for larger files) 📖 Manual Coverage Systems Covered Engine Service Repair: Comprehensive coverage including diagnostics, overhaul, component testing, and specifications. Transmission Service Repair: Detailed procedures for both manual and automatic transmissions, including clutch, gearbox, and transfer case. Brake System: Covers hydraulic system, ABS, EBD, brake pads, discs, calipers, and parking brake. Electrical System: Extensive coverage of wiring diagrams, component locations, diagnostic procedures for electrical faults. Suspension: Front and rear suspension components, alignment, shock absorbers, springs, and bushings. Steering: Power steering system, steering column, linkages, and troubleshooting. Cooling System: Radiator, water pump, thermostat, hoses, fans, and coolant specifications. Fuel Injection: Detailed information on fuel injection systems, injectors, fuel pump, and pressure regulator. Fuel System: Fuel tank, lines, filters, and evaporative emission control system. Emission System: Catalytic converter, EGR system, O2 sensors, and emission control components. Heater Air Conditional: HVAC system components, refrigerant, operation, and troubleshooting. Engine Control System: ECU, sensors, actuators, diagnostic...
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Ssangyong Rexton I & II EWD LHD Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Rexton
Generation:
I & II
Chassis Code:
G200 (Rexton I), G200/G200W (Rexton II)
Body Style:
SUV
Drive Type:
EWD (Electronic 4WD)
Steering Side:
LHD (Left-Hand Drive)
👋 Introduction
Market Position
Target Audience:
Technicians, mechanics, DIY enthusiasts, and anyone wanting to repair or learn about the SsangYong Rexton.
Value Proposition:
Provides comprehensive factory-level information at a competitive price for efficient vehicle repair and maintenance.
Competitive Analysis
Alternative Resources:
Highlights the inconvenience and cost of searching through numerous physical bookstores for repair information.
Key Features
Completeness:
Official full complete factory service repair manual.
Accessibility:
Instant download provides immediate access to crucial repair data.
User Support:
Customer support available for concerns or download issues.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF
Page Count Estimate:
Hundreds to Thousands
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip (for larger files)
📖 Manual Coverage
Systems Covered
Engine Service Repair:
Comprehensive coverage including diagnostics, overhaul, component testing, and specifications.
Transmission Service Repair:
Detailed procedures for both manual and automatic transmissions, including clutch, gearbox, and transfer case.
Brake System:
Covers hydraulic system, ABS, EBD, brake pads, discs, calipers, and parking brake.
Electrical System:
Extensive coverage of wiring diagrams, component locations, diagnostic procedures for electrical faults.
Suspension:
Front and rear suspension components, alignment, shock absorbers, springs, and bushings.
Steering:
Power steering system, steering column, linkages, and troubleshooting.
Cooling System:
Radiator, water pump, thermostat, hoses, fans, and coolant specifications.
Fuel Injection:
Detailed information on fuel injection systems, injectors, fuel pump, and pressure regulator.
Fuel System:
Fuel tank, lines, filters, and evaporative emission control system.
Emission System:
Catalytic converter, EGR system, O2 sensors, and emission control components.
Heater Air Conditional:
HVAC system components, refrigerant, operation, and troubleshooting.
Engine Control System:
ECU, sensors, actuators, diagnostic trouble codes (DTCs), and PCM strategies.
Chassis Body:
Frame construction, body panels, doors, hinges, latches, and exterior trim.
Restraint System:
Airbag system, seatbelts, and SRS component locations and diagnostics.
Interior:
Dashboard, seats, trim panels, and interior lighting.
Differential Drive:
Front and rear differentials, drive shafts, and CV joints.
Axle:
Front and rear axle components, wheel bearings, and seals.
General Maintenance:
Routine checks, fluid level checks, filter replacements, and lubrication.
Troubleshooting:
Systematic approach to diagnosing common and complex vehicle problems.
Periodic Lubrication:
Specific lubrication points, intervals, and recommended lubricant types.
Procedures Included
Engine Overhaul:
Detailed step-by-step instructions for engine disassembly, inspection, and reassembly.
Transmission Rebuild:
Procedures for rebuilding automatic and manual transmissions, including torque specifications and component identification.
Brake Bleeding:
Correct procedures for bleeding the brake system, including ABS-equipped vehicles.
Electrical Component Replacement:
Instructions for replacing various electrical components such as alternators, starters, sensors, and ECUs.
Suspension Alignment:
Guidelines and specifications for front and rear wheel alignment.
Fuel Injector Cleaning Testing:
Procedures for cleaning and testing fuel injectors.
HVAC System Diagnosis Recharge:
Steps for diagnosing HVAC issues and recharging the refrigerant system.
Timing Belt Replacement:
Detailed instructions for timing belt replacement, critical for preventing engine damage.
Differential Oil Change:
Procedures for changing and refilling differential oil.
Airbag System Diagnosis:
Procedures for diagnosing and safely working with the SRS system.
Chassis Lubrication:
Identification of lubrication points and recommended service intervals.
Technical Depth
Diagnostics:
In-depth diagnostic procedures, including symptom-based troubleshooting and use of diagnostic tools.
Repair Specifications:
Precise torque values, clearances, tolerances, and assembly instructions for all major components.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all vehicle systems.
Component Testing:
Procedures for testing individual components (e.g., sensors, actuators, solenoids) to verify functionality.
Factory Data:
Technical data maintained at the original manufacturer's book level.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality:
High Quality, Printable
Searchability:
Likely searchable text within PDF files (dependent on original scanning quality).
Compress Format:
May require unzipper for larger manuals (e.g., .zip or .rar).
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Family:
Likely Korean-developed diesel engines (e.g., OM602 derived or similar variants) and potentially Mercedes-Benz sourced engines in some markets/generations.
Engine Displacement Examples:
2.3L, 2.7L (common for Rexton I and II, often diesel).
Performance
Horsepower Range Estimate:
Approximately 120-165 hp depending on specific engine and tuning.
Torque Range Estimate:
Approximately 240-340 Nm depending on specific engine and tuning.
Fuel System
Fuel Delivery:
Common Rail Direct Injection (CRDI) for diesel variants, likely multi-point injection for gasoline variants (if offered).
Turbocharger:
Likely features a turbocharger with intercooler for diesel engines to enhance performance and efficiency.
🔧 Transmission
Standard
Transmission Type Examples:
5-speed Manual Transmission, 4-speed or 5-speed Automatic Transmission.
Optional
Transmission Type Examples:
Automatic transmission variants were common options.
Features
Drivetrain Options:
Electronically controlled 4WD (EWD) system with selectable modes.
Gear Ratios:
Specific gear ratios for each transmission variant would be detailed within the manual.
📐 Dimensions
Exterior
Length Estimate:
Approx. 4650-4740 mm
Width Estimate:
Approx. 1870-1890 mm
Height Estimate:
Approx. 1730-1745 mm
Weights
Curb Weight Estimate:
Approx. 1900-2100 kg
Gross Vehicle Weight Estimate:
Exceeds 2600 kg, specific to GVWR.
Towing Capacity Estimate:
Typically rated for towing up to 2000-2500 kg (braked).
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by market and specific testing agency (e.g., Euro NCAP). Early Rexton models might not have extensive modern crash data publicly available.
Active Features
Electronic Stability Control:
Likely available on later Rexton II models, but may be optional or absent on earlier Rexton I.
Anti-Lock Braking System:
Standard on most Rexton models.
Electronic Brakeforce Distribution:
Commonly paired with ABS.
Passive Features
Airbags:
Front airbags for driver and passenger, potentially side airbags on higher trims or later models.
Seatbelts:
Three-point seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted radio/CD player, potentially with CD changer or MP3 capability in later models. Aftermarket integration guidance may be absent.
Navigation:
Optional GPS navigation system available on some higher trim levels or later models.
Driver Assistance
Parking Sensors:
Rear parking sensors might be available on higher trims.
Cruise Control:
Standard on most models.
Connectivity
Auxiliary Input:
Likely an auxiliary input jack for audio devices on later models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, depending on engine type and driving conditions. Consult manual for exact intervals.
Transmission Fluid Interval:
Automatic transmission fluid should be checked regularly and changed every 60,000-100,000 km. Manual transmission fluid change is less frequent, typically 100,000-160,000 km.
Timing Belt Interval:
Crucial for diesel engines; typically 70,000-100,000 km or 5-7 years. This manual will specify the exact interval and procedures.
Fluid Specifications
Engine Oil Type:
Diesel engines typically require API CI-4 or higher, SAE 5W-30 or 10W-30 synthetic or semi-synthetic oil. Gasoline variants will have different specifications. Manual will list exact specifications.
Coolant Type:
Ethylene glycol-based antifreeze, typically a long-life formulation (e.g., HOAT or OAT). Manual will specify color and type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Type Auto:
Dexron III/VI or equivalent for older automatics; specific ATF for newer models. Manual will be precise.
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil, with specific viscosity grade (e.g., 75W-90). Manual will specify.
Known Issues
Diesel Particulate Filter Clogging:
Common in modern diesels with heavy city driving; manual may offer regeneration procedures.
Edbcontext Issues:
Potential issues with sensors or actuators in the engine control unit or transmission control module.
Suspension Wear:
Ball joints, bushings, and shock absorbers can experience wear over time, especially with off-road use.
Radiator Leaks:
As with many vehicles, radiators can develop leaks over time.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Model Evolution
Generation I Introduction:
Launched in 2001, based on a ladder-frame chassis and often utilizing Mercedes-Benz driveline components (e.g., engines and transmissions).
Generation Ii Introduction:
Launched around 2006 with updated styling, interior, and powertrain options, including revised engines and transmission options.
Production
Production Period:
Rexton I: 2001–2006; Rexton II: 2006–2017 (with facelifts).
🏆 Awards & Recognition
Recognitions
Specific Awards:
No widely publicized major awards or significant critical acclaim reported for the Rexton I/II in major automotive publications. It was often positioned as a budget-friendly alternative in the SUV segment.
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