Ssangyong Rexton Y200 2001-2006 Full Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Ssangyong Model: Rexton Model Code: Y200 Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Chassis Code: Y200 ๐ Introduction Market Position Positioning: Rugged, mid-size SUV known for its robust construction and off-road capability Competitive Analysis Competitors: Competed against vehicles like the Toyota 4Runner, Mitsubishi Pajero (Montero), and other body-on-frame SUVs of its era Key Features Design Philosophy: Emphasized a strong ladder frame chassis and capable four-wheel-drive system for versatility Target Audience: Individuals seeking a capable, durable SUV for diverse driving conditions, including light to moderate off-roading ๐ Manual Details Coverage Areas Primary Coverage: Full Service and Repair Page Count Estimated Pages: Comprehensive (Specific count not provided, implies extensive detail) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Windows Versions, macOS ๐ Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, tuning, and specifications Transmission: Service, repair, and overhaul procedures for both automatic and manual transmissions Drivetrain: Four-wheel drive (4WD) system, transfer case, differentials, driveshafts, axles Suspension: Front and rear suspension components, steering system, wheel alignment Brakes: Hydraulic system, ABS, disc and drum brake components, service and repair Electrical System: Comprehensive wiring diagrams, component testing, diagnostics, charging system, ignition system Fuel System: Fuel injection, fuel pump, fuel tank, lines, and filters Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications Exhaust System: Catalytic converter, mufflers, pipes, emissions control HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair Body And Chassis: Body panels, interior trim, doors, windows, chassis components Dashboard And Gauges: Operation, troubleshooting, and repair of instrument cluster and warning lights. Lighting System: Headlights, taillights, interior lighting, and associated controls. Tire And Wheel: Specifications, pressure, and replacement guidance. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation Repair: Step-by-step repair procedures for all major components and systems Rebuild: Complete engine and transmission rebuild procedures Refurbish: Procedures for restoring components and systems Restoration: Guidance for full vehicle restoration Wiring Diagrams: Detailed, integrated wiring schematics for electrical troubleshooting Recalibration: Procedures for recalibrating sensors or modules after component replacement. Alignment Specifications: Wheel alignment specifications and procedures. Technical Depth Depth: Professional Technician Level User Accessibility: Suitable for DIY mechanics with adequate data Diagnostics Tools: May reference proprietary diagnostic tools or general OBD-II scanners where applicable. ๐ Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable (All pages) Binding Type Binding: Digital (Printable from PDF) Paper Type Paper Type: N/A (Digital delivery) Features Illustrations: Detailed illustrations, drawings, and photos Instructions: Numbered, step-by-step instructions Notes Cautions Warnings: Included throughout for critical information Troubleshooting Integration: Troubleshooting and electrical service combined with wiring diagrams Table Of Contents: Numbered and easy to use for quick information retrieval Part Identification: Enlarged insets for detailed part examination โ๏ธ Engine Specifications Primary Engine Engine Options: Likely featured Mercedes-Benz derived diesel engines (e.g., OM602, OM601 variants, or similar) and potentially gasoline engines. Specific Y200 engine variants are crucial and would be detailed in the manual. Performance Diesel Power Estimate: Typically in the range of 100-120 HP and 200-250 Nm of torque for 2.0L/2.3L diesel variants common in this era, though larger displacements were also available. Fuel System Injection Type: Likely indirect or direct injection diesel, with potential for gasoline port or direct injection depending on engine option. Emission Controls Emission Standards: Varies by market, likely Euro III compliant for European markets. ๐ง Transmission Standard Transmission Type: Likely offered with both 5-speed manual and 4-speed automatic transmissions. Optional Transmission Options: 4-speed automatic transmission (likely Mercedes-Benz sourced). Features Drive System: Part-time or full-time Four-wheel drive (4WD) with low-range gearing. ๐ Dimensions Exterior Body Style: 5-door SUV Wheelbase: Approximately 2755 mm (108.5 inches) Weights Curb Weight: Typically ranging from 1800 kg to 2100 kg depending on engine and drivetrain. Gross Vehicle Weight Rating: Around 2600-2800 kg ๐ก๏ธ Safety Features Ratings Crash Test Ratings: Information may vary by market and testing agency. Early models might not have comprehensive modern ratings. Active Features ABS: Anti-lock Braking System (ABS) typically standard or optional. Traction Control: Traction Control System (TCS) may have been available on higher trims or later models. Passive Features Airbags: Driver and front passenger airbags standard. ๐ก Technology Features Infotainment Audio System: Likely a basic AM/FM/CD player, potentially with cassette or navigation options on higher trims. Driver Assistance Cruise Control: Typically available on most trims. Connectivity Connectivity Features: Limited by era; may include power outlets and basic audio inputs. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months for diesel engines, depending on driving conditions. Timing Belt Replacement: If equipped with a timing belt, intervals typically 60,000-90,000 miles (100,000-150,000 km). The manual will specify the exact interval and procedure. Fluid Specifications Engine...
Step-by-step repair procedures for all major components and systems
Rebuild:
Complete engine and transmission rebuild procedures
Refurbish:
Procedures for restoring components and systems
Restoration:
Guidance for full vehicle restoration
Wiring Diagrams:
Detailed, integrated wiring schematics for electrical troubleshooting
Recalibration:
Procedures for recalibrating sensors or modules after component replacement.
Alignment Specifications:
Wheel alignment specifications and procedures.
Technical Depth
Depth:
Professional Technician Level
User Accessibility:
Suitable for DIY mechanics with adequate data
Diagnostics Tools:
May reference proprietary diagnostic tools or general OBD-II scanners where applicable.
๐ Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable (All pages)
Binding Type
Binding:
Digital (Printable from PDF)
Paper Type
Paper Type:
N/A (Digital delivery)
Features
Illustrations:
Detailed illustrations, drawings, and photos
Instructions:
Numbered, step-by-step instructions
Notes Cautions Warnings:
Included throughout for critical information
Troubleshooting Integration:
Troubleshooting and electrical service combined with wiring diagrams
Table Of Contents:
Numbered and easy to use for quick information retrieval
Part Identification:
Enlarged insets for detailed part examination
โ๏ธ Engine Specifications
Primary Engine
Engine Options:
Likely featured Mercedes-Benz derived diesel engines (e.g., OM602, OM601 variants, or similar) and potentially gasoline engines. Specific Y200 engine variants are crucial and would be detailed in the manual.
Performance
Diesel Power Estimate:
Typically in the range of 100-120 HP and 200-250 Nm of torque for 2.0L/2.3L diesel variants common in this era, though larger displacements were also available.
Fuel System
Injection Type:
Likely indirect or direct injection diesel, with potential for gasoline port or direct injection depending on engine option.
Emission Controls
Emission Standards:
Varies by market, likely Euro III compliant for European markets.
๐ง Transmission
Standard
Transmission Type:
Likely offered with both 5-speed manual and 4-speed automatic transmissions.
Part-time or full-time Four-wheel drive (4WD) with low-range gearing.
๐ Dimensions
Exterior
Body Style:
5-door SUV
Wheelbase:
Approximately 2755 mm (108.5 inches)
Weights
Curb Weight:
Typically ranging from 1800 kg to 2100 kg depending on engine and drivetrain.
Gross Vehicle Weight Rating:
Around 2600-2800 kg
๐ก๏ธ Safety Features
Ratings
Crash Test Ratings:
Information may vary by market and testing agency. Early models might not have comprehensive modern ratings.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard or optional.
Traction Control:
Traction Control System (TCS) may have been available on higher trims or later models.
Passive Features
Airbags:
Driver and front passenger airbags standard.
๐ก Technology Features
Infotainment
Audio System:
Likely a basic AM/FM/CD player, potentially with cassette or navigation options on higher trims.
Driver Assistance
Cruise Control:
Typically available on most trims.
Connectivity
Connectivity Features:
Limited by era; may include power outlets and basic audio inputs.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months for diesel engines, depending on driving conditions.
Timing Belt Replacement:
If equipped with a timing belt, intervals typically 60,000-90,000 miles (100,000-150,000 km). The manual will specify the exact interval and procedure.
Fluid Specifications
Engine Oil Type Diesel:
API CF or CG-4, SAE 10W-30 or 15W-40 (check manual for specific viscosity and API classification).
Coolant Type:
Ethylene glycol based coolant, typically a green or blue color. Consult manual for specific type and OAT/HOAT designation.
Transmission Fluid Automatic:
Dexron-III or equivalent (check manual for specific MB spec).
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Problems:
Potential issues can include turbocharger problems, EGR valve issues (diesel), glow plug failures, and some electrical gremlins. Body-on-frame vehicles of this era can also experience rust.
Service Bulletins:
The manual will contain information on common faults and recommended fixes, potentially referencing manufacturer service bulletins.
๐ Vehicle History
Brand Heritage
Brand Origin:
SsangYong Motor Company is a South Korean manufacturer known for its SUVs and off-road vehicles, often utilizing Mercedes-Benz technology in its early development.
Model Evolution
First Generation:
The Rexton (Y200) was SsangYong's first major SUV offering in the new millennium, building on the Korando lineage but targeting a more premium and comfortable segment.
Production
Manufacturing Location:
South Korea
Production Years Model:
2001-2006 (for the Y200 series)
๐ Awards & Recognition
Recognitions
Awards:
Specific awards for the Y200 Rexton are not widely publicized. Its market success was more niche compared to dominant players.