SsangYong Rexton I Rexton II Rexton W Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
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🏷️ Basic Information Identification Make: SsangYong Model: Rexton I / Rexton II / Rexton W Generation Production Years: 2001-2016 Codes Platform Codes: RJ (Rexton I), Y250 (Rexton II/W) 👋 Introduction Market Position Vehicle Segment: Mid-size/Large SUV, body-on-frame construction Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops. Competitive Analysis Key Competitors: Mitsubishi Pajero Sport, Hyundai Terracan, Kia Sorento (first generation), Ford Everest. Key Features Manual Benefits: Cost savings on repairs, empowerment of owners to maintain their vehicles, comprehensive coverage of all systems. Vehicle Strengths: Robust chassis, capable off-road performance (especially with 4WD), spacious interior, often competitive pricing. 📋 Manual Details Coverage Areas Geographical Coverage: Global (specifications may vary by region) Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete workshop manual) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel system (mechanical and electronic), intake manifold, exhaust manifold. Engine Electrical: Ignition system, starter system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, emissions control systems. Transmission Drivetrain: Manual transmission, automatic transmission (including transfer case and differentials), clutch system, driveshafts, axles, wheel bearings. Suspension Steering: Front suspension (independent double wishbone, coil springs, shock absorbers), rear suspension (multi-link, coil springs, shock absorbers), steering system (power steering pump, rack and pinion), wheel alignment specifications. Brakes: Front and rear brake system (disc brakes), parking brake, anti-lock braking system (ABS), electronic brake-force distribution (EBD), brake fluid specifications and bleeding procedures. Body Chassis: Body structure, chassis frame, exterior panels, doors, hood, tailgate, interior trim, seats, glass, body sealing, rust prevention. Electrical Electronics: Complete vehicle electrical system, battery, charging system, lighting (headlights, taillights, interior), wipers and washers, horn, power windows, central locking, instrument cluster, wiring diagrams, fuses, relays, body control module (BCM). HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant type, charging procedures, component testing. Safety Restraints: Airbag system, seat belts, pre-tensioners, SRS module diagnostics. Procedures Included Maintenance: Regular maintenance checks, oil changes, filter replacements, fluid top-ups, tire rotations, brake pad inspection, battery maintenance. Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation. Repair: Step-by-step repair instructions for all major vehicle components, including engine overhaul, transmission repair, suspension component replacement, brake system overhaul, electrical component repair. Installation: Installation guides for specific components or accessories (where applicable). Technical Depth Depth Of Information: Comprehensive, covering basic maintenance to complete engine rebuilds and complex electrical diagnostics. Diagnostic Capabilities: Detailed diagnostic procedures, including sensor data interpretation and component testing. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Printability: High-quality, printable pages; zoomable for detailed examination of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: Diverse range including 2.7L Diesel (OM662LA), 2.9L Diesel (OM662LA variant or similar), 3.2L Diesel (OM612 variants or similar Mercedes-Benz sourced), 2.7L Turbo Diesel (OM662LA-based), 3.6L V6 Petrol (M112 Mercedes-Benz sourced). Performance Power Output Range: Approximately 120 HP to 200 HP depending on engine and specific tuning. Torque Output Range: Approximately 230 Nm to 400 Nm depending on engine and specific tuning. Fuel System Fuel Delivery Systems: Common Rail Direct Injection (CRDi) for diesel engines, Electronic Fuel Injection (EFI) for petrol engines. 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission (MT) for many variants. Optional Optional Transmission Type: 5-speed or 4-speed Automatic Transmission (AT), often sourced from Mercedes-Benz (e.g., 722.6 variant for some models). Features Drivetrain Options: Part-time 4WD (Rexton I) or full-time 4WD systems with low-range transfer case on many models. 📐 Dimensions Exterior Length: Approx. 4700-4750 mm Width: Approx. 1870-1900 mm Height: Approx. 1770-1800 mm Wheelbase: Approx. 2820-2830 mm Cargo Cargo Volume: Variable, typically around 850-900 liters behind the second row, expandable with seats folded. Weights Curb Weight: Approx. 1900-2100 kg Gross Vehicle Weight Rating: Approx. 2700-2900 kg 🛡️ Safety Features Ratings Crash Test History: Varies by market and specific model year; generally considered a robust vehicle for its class but may not meet modern stringent safety standards without specific regional enhancements. Active Features Active Safety Features: ABS, EBD (standard on most models), Traction Control System (TCS) on higher trims and later models, Electronic Stability Program (ESP) on later models. Passive Features Passive Safety Features: Dual front airbags, side airbags (on some models), 3-point seat belts with pre-tensioners, reinforced body structure. 💡 Technology Features Infotainment Infotainment Systems: Varies significantly by trim and year. Base models may have basic AM/FM radio with CD player. Higher trims and later models offer touchscreen infotainment systems with navigation, Bluetooth connectivity, and rearview camera integration. Driver Assistance Driver Assistance Features: Limited on early models. Later models may include parking sensors, rearview cameras, and cruise control. Connectivity...
Ignition system, starter system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, emissions control systems.
Transmission Drivetrain:
Manual transmission, automatic transmission (including transfer case and differentials), clutch system, driveshafts, axles, wheel bearings.
Suspension Steering:
Front suspension (independent double wishbone, coil springs, shock absorbers), rear suspension (multi-link, coil springs, shock absorbers), steering system (power steering pump, rack and pinion), wheel alignment specifications.
Brakes:
Front and rear brake system (disc brakes), parking brake, anti-lock braking system (ABS), electronic brake-force distribution (EBD), brake fluid specifications and bleeding procedures.
Body Chassis:
Body structure, chassis frame, exterior panels, doors, hood, tailgate, interior trim, seats, glass, body sealing, rust prevention.
Electrical Electronics:
Complete vehicle electrical system, battery, charging system, lighting (headlights, taillights, interior), wipers and washers, horn, power windows, central locking, instrument cluster, wiring diagrams, fuses, relays, body control module (BCM).
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant type, charging procedures, component testing.
Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation.
Repair:
Step-by-step repair instructions for all major vehicle components, including engine overhaul, transmission repair, suspension component replacement, brake system overhaul, electrical component repair.
Installation:
Installation guides for specific components or accessories (where applicable).
Technical Depth
Depth Of Information:
Comprehensive, covering basic maintenance to complete engine rebuilds and complex electrical diagnostics.
Diagnostic Capabilities:
Detailed diagnostic procedures, including sensor data interpretation and component testing.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Printability:
High-quality, printable pages; zoomable for detailed examination of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Diverse range including 2.7L Diesel (OM662LA), 2.9L Diesel (OM662LA variant or similar), 3.2L Diesel (OM612 variants or similar Mercedes-Benz sourced), 2.7L Turbo Diesel (OM662LA-based), 3.6L V6 Petrol (M112 Mercedes-Benz sourced).
Performance
Power Output Range:
Approximately 120 HP to 200 HP depending on engine and specific tuning.
Torque Output Range:
Approximately 230 Nm to 400 Nm depending on engine and specific tuning.
Fuel System
Fuel Delivery Systems:
Common Rail Direct Injection (CRDi) for diesel engines, Electronic Fuel Injection (EFI) for petrol engines.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission (MT) for many variants.
Optional
Optional Transmission Type:
5-speed or 4-speed Automatic Transmission (AT), often sourced from Mercedes-Benz (e.g., 722.6 variant for some models).
Features
Drivetrain Options:
Part-time 4WD (Rexton I) or full-time 4WD systems with low-range transfer case on many models.
📐 Dimensions
Exterior
Length:
Approx. 4700-4750 mm
Width:
Approx. 1870-1900 mm
Height:
Approx. 1770-1800 mm
Wheelbase:
Approx. 2820-2830 mm
Cargo
Cargo Volume:
Variable, typically around 850-900 liters behind the second row, expandable with seats folded.
Weights
Curb Weight:
Approx. 1900-2100 kg
Gross Vehicle Weight Rating:
Approx. 2700-2900 kg
🛡️ Safety Features
Ratings
Crash Test History:
Varies by market and specific model year; generally considered a robust vehicle for its class but may not meet modern stringent safety standards without specific regional enhancements.
Active Features
Active Safety Features:
ABS, EBD (standard on most models), Traction Control System (TCS) on higher trims and later models, Electronic Stability Program (ESP) on later models.
Passive Features
Passive Safety Features:
Dual front airbags, side airbags (on some models), 3-point seat belts with pre-tensioners, reinforced body structure.
💡 Technology Features
Infotainment
Infotainment Systems:
Varies significantly by trim and year. Base models may have basic AM/FM radio with CD player. Higher trims and later models offer touchscreen infotainment systems with navigation, Bluetooth connectivity, and rearview camera integration.
Driver Assistance
Driver Assistance Features:
Limited on early models. Later models may include parking sensors, rearview cameras, and cruise control.
Connectivity
Connectivity Options:
USB ports, auxiliary input, Bluetooth (on select models and trims).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on engine oil type and driving conditions. Consult manual for specific engine recommendations.
Air Filter Replacement:
Every 20,000-30,000 km or as per manual, more frequently in dusty conditions.
Fuel Filter Replacement:
Diesel: Every 40,000-60,000 km. Petrol: Less frequent, consult manual.
Fluid Specifications
Engine Oil Specifications:
Varies by engine. Diesel engines often require API CJ-4 or CK-4 compliant synthetic oils (e.g., 5W-30, 10W-30). Petrol engines may require API SN/SP or ILSAC GF-5/GF-6 compliant oils (e.g., 5W-30, 10W-40). Always refer to the specific manual for exact grade and API/ILSAC ratings.
Transmission Fluid Specifications Auto:
Typically Dexron III/VI compatible fluid for older automatics, or specific ATF fluids for Mercedes-Benz sourced transmissions (e.g., ATF 7134). Consult manual for precise type.
Coolant Specifications:
Ethylene glycol-based coolant with anti-corrosion additives. Usually a long-life (OAT) or HOAT type. Refer to manual for specific colour and type (e.g., G12 or similar).
Brake Fluid Specifications:
DOT 3 or DOT 4.
Known Issues
Common Complaints Diesel:
Potential issues with turbocharger reliability (especially on older models), glow plug system faults, EGR valve clogging, exhaust manifold cracking, injector problems.
Common Complaints General:
Rusting on chassis and body panels (particularly older models), occasional electrical gremlins, suspension component wear (bushings, ball joints), power window regulator failures.
Transmission Issues Auto:
Some automatic transmissions, particularly older ones, may exhibit harsh shifting or delayed engagement. Fluid and filter changes are critical for longevity.
📚 Vehicle History
Brand Heritage
Ssangyong Heritage:
SsangYong Motor Company has a history dating back to 1954, initially involved in military vehicle production. Known for producing rugged, utility-focused vehicles, often utilizing technology licensed from other manufacturers (notably Mercedes-Benz for powertrains in early models).
Model Evolution
Rexton Evolution:
The Rexton series represents SsangYong's flagship SUV. The Rexton I (RJ platform, 2001-2006) was the first generation, built on a robust ladder frame chassis. The Rexton II (Y250 platform, 2006-2012) introduced updated styling and improved technology, often featuring Mercedes-Benz derived engines and transmissions. The Rexton W (also Y250 platform, 2012-2017) brought further styling revisions and powertrain updates. This manual covers this entire generational span.
Production
Manufacturing Locations:
Primarily South Korea (Pyeongtaek).
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
SsangYong Rexton has received varied reviews over its production run, with common praise for its value proposition, off-road capability, and robustness, while criticism often focused on interior refinement, fuel economy (especially older diesel engines), and dealer network compared to mainstream brands.
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