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SsangYong Rexton Workshop Service Repair Manual 2001-2003 (1 991 Pages Searchable Bookmarked iPad-ready)

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๐Ÿท๏ธ Basic Information Identification Make: SsangYong Model: Rexton Generation Production Years: 2001-2003 Codes Model Code: RJ (for this generation) ๐Ÿ‘‹ Introduction Market Position Positioning: The SsangYong Rexton, launched in 2001, was positioned as a robust, body-on-frame SUV designed for both on-road comfort and off-road capability, competing in a segment with established players like the Mitsubishi Pajero and Land Rover Discovery. Competitive Analysis Competitors: Key competitors during its production years included the Mitsubishi Pajero/Montero, Land Rover Discovery, Jeep Grand Cherokee, and similar large SUVs. Key Features Vehicle Features: Body-on-frame construction for durability and towing capacity, available four-wheel drive systems, spacious interior, and a focus on ruggedness. Manual Value Benefits: Provides dealership-level service information for DIY repairs and maintenance, saving owners significant costs on professional servicing. Its comprehensive nature ensures accuracy and completeness for any repair task. ๐Ÿ“‹ Manual Details Coverage Areas Vehicle Models Covered: All SsangYong Rexton models and engines produced between 2001 and 2003. Page Count Total Pages: 1991 Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF ๐Ÿ“– Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Control System, Cooling System, Fuel System, Exhaust System, Lubrication System, Transmission (Manual and Automatic), Clutch System, Drive Shafts, Differential Case Assembly, Drive Axles. Chassis: Brake System (including Brake Master Cylinder, Brake Booster, Brake Actuator), Suspension System (Front and Rear, including Shock Absorbers and Coil Springs), Steering System (including Power Steering, Steering Column), Wheel and Tire System, Wheel Alignment. Body & Electrical: Body Repair, Exterior (Body Panels, Doors, Hood, Bumpers), Interior (Trim, Seating, Instrument Panel), Lighting System (Headlamps, Tail Lamps, Interior Lights), Wiper and Washer System, Power Window Control System, Power Door Lock Control System, Sun Roof System, Air Conditioning System, Supplemental Restraint System (SRS - Airbags, Seat Belts), Combination Meter, Audio System, Charging System, Starting System, Ignition System. Procedures Included Maintenance: Regular maintenance checks, fluid level checks and changes, filter replacements, lubrication points, tire rotation, battery maintenance. Repair: Step-by-step repair procedures for all major vehicle systems, including engine disassembly/reassembly, transmission overhaul, brake component replacement, suspension work, body panel repair, and electrical component diagnostics and repair. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) explanation, common fault diagnosis for various systems, electrical system troubleshooting with wiring diagrams. Technical Depth Depth: Comprehensive, covering everything from routine maintenance and adjustments to complete component overhauls and rebuilds. Detailed illustrations, diagrams, and step-by-step instructions cater to both DIY enthusiasts and professional mechanics. ๐Ÿ“Š Manual Specifications File Format Compatibility: Compatible with all PC-based Windows operating systems, Mac, and Linux. Print Quality Printability: All pages are printable, allowing users to print specific sections or the entire manual. Binding Type Binding: Digital (PDF format) Paper Type Paper Quality: Not applicable (digital format); content is presented in a high-quality, searchable, and bookmarked PDF. โš™๏ธ Engine Specifications Primary Engine Engine Options: The Rexton from this era was typically offered with a range of diesel engines, including Mercedes-Benz derived units like the 2.9L (OM662) and 2.7L (OM612) common rail diesel engines. Gasoline options might also have been available in certain markets. The manual covers all engine variants. Performance Typical Hp Range: Diesel engines in this period generally produced between 120-165 horsepower, with torque figures ranging from approximately 250-340 Nm, depending on the specific engine variant. Fuel System Injection Type: Common Rail Direct Injection (CRDI) for diesel engines, ensuring better fuel efficiency and emissions control. ๐Ÿ”ง Transmission Standard Transmission Type: Likely a 5-speed manual transmission was standard on base models. Automatic transmissions were also widely available and common in this segment. Optional Automatic Transmission: A Mercedes-Benz sourced 5-speed automatic transmission was a prevalent option, offering smooth gear changes and good drivability. Features Drivetrain: Part-time or full-time 4WD systems were offered, often with low-range gearing for enhanced off-road capability. The manual covers servicing and repair for both 2WD and 4WD configurations. ๐Ÿ“ Dimensions Exterior Overall Length: Approximately 4,720 mm (185.8 inches) for most configurations. Overall Width: Approximately 1,865 mm (73.4 inches). Overall Height: Approximately 1,795 mm (70.7 inches). Weights Curb Weight: Typically ranging from 1,900 kg to 2,100 kg (4,189 lbs to 4,630 lbs) depending on engine and drivetrain. Towing Capacity: Generally rated for towing capacities up to 2,000 kg (4,400 lbs) with braked trailers. ๐Ÿ›ก๏ธ Safety Features Ratings Crash Test Results: Specific crash test ratings from independent agencies (like Euro NCAP or NHTSA) for the 2001-2003 Rexton are not widely publicized or may vary by region. However, the vehicle was equipped with standard safety features for its time. Active Features ABS: Anti-lock Braking System (ABS) was typically standard or available. Traction Control: Traction control systems may have been available on higher trim levels or as an option. Passive Features Airbags: Front airbags for driver and passenger were standard. Side airbags and curtain shield airbags were available on some models or as options. Seat Belts: Three-point seat belts with pre-tensioners for front...
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SsangYong Rexton Workshop Service Repair Manual 2001-2003 (1 991 Pages Searchable Bookmarked iPad-ready)
๐Ÿท๏ธ Basic Information
Identification
Make:
SsangYong
Model:
Rexton
Generation
Production Years:
2001-2003
Codes
Model Code:
RJ (for this generation)
๐Ÿ‘‹ Introduction
Market Position
Positioning:
The SsangYong Rexton, launched in 2001, was positioned as a robust, body-on-frame SUV designed for both on-road comfort and off-road capability, competing in a segment with established players like the Mitsubishi Pajero and Land Rover Discovery.
Competitive Analysis
Competitors:
Key competitors during its production years included the Mitsubishi Pajero/Montero, Land Rover Discovery, Jeep Grand Cherokee, and similar large SUVs.
Key Features
Vehicle Features:
Body-on-frame construction for durability and towing capacity, available four-wheel drive systems, spacious interior, and a focus on ruggedness.
Manual Value
Benefits:
Provides dealership-level service information for DIY repairs and maintenance, saving owners significant costs on professional servicing. Its comprehensive nature ensures accuracy and completeness for any repair task.
๐Ÿ“‹ Manual Details
Coverage Areas
Vehicle Models Covered:
All SsangYong Rexton models and engines produced between 2001 and 2003.
Page Count
Total Pages:
1991
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
๐Ÿ“– Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Engine Control System, Cooling System, Fuel System, Exhaust System, Lubrication System, Transmission (Manual and Automatic), Clutch System, Drive Shafts, Differential Case Assembly, Drive Axles.
Chassis:
Brake System (including Brake Master Cylinder, Brake Booster, Brake Actuator), Suspension System (Front and Rear, including Shock Absorbers and Coil Springs), Steering System (including Power Steering, Steering Column), Wheel and Tire System, Wheel Alignment.
Body & Electrical:
Body Repair, Exterior (Body Panels, Doors, Hood, Bumpers), Interior (Trim, Seating, Instrument Panel), Lighting System (Headlamps, Tail Lamps, Interior Lights), Wiper and Washer System, Power Window Control System, Power Door Lock Control System, Sun Roof System, Air Conditioning System, Supplemental Restraint System (SRS - Airbags, Seat Belts), Combination Meter, Audio System, Charging System, Starting System, Ignition System.
Procedures Included
Maintenance:
Regular maintenance checks, fluid level checks and changes, filter replacements, lubrication points, tire rotation, battery maintenance.
Repair:
Step-by-step repair procedures for all major vehicle systems, including engine disassembly/reassembly, transmission overhaul, brake component replacement, suspension work, body panel repair, and electrical component diagnostics and repair.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) explanation, common fault diagnosis for various systems, electrical system troubleshooting with wiring diagrams.
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance and adjustments to complete component overhauls and rebuilds. Detailed illustrations, diagrams, and step-by-step instructions cater to both DIY enthusiasts and professional mechanics.
๐Ÿ“Š Manual Specifications
File Format
Compatibility:
Compatible with all PC-based Windows operating systems, Mac, and Linux.
Print Quality
Printability:
All pages are printable, allowing users to print specific sections or the entire manual.
Binding Type
Binding:
Digital (PDF format)
Paper Type
Paper Quality:
Not applicable (digital format); content is presented in a high-quality, searchable, and bookmarked PDF.
โš™๏ธ Engine Specifications
Primary Engine
Engine Options:
The Rexton from this era was typically offered with a range of diesel engines, including Mercedes-Benz derived units like the 2.9L (OM662) and 2.7L (OM612) common rail diesel engines. Gasoline options might also have been available in certain markets. The manual covers all engine variants.
Performance
Typical Hp Range:
Diesel engines in this period generally produced between 120-165 horsepower, with torque figures ranging from approximately 250-340 Nm, depending on the specific engine variant.
Fuel System
Injection Type:
Common Rail Direct Injection (CRDI) for diesel engines, ensuring better fuel efficiency and emissions control.
๐Ÿ”ง Transmission
Standard
Transmission Type:
Likely a 5-speed manual transmission was standard on base models. Automatic transmissions were also widely available and common in this segment.
Optional
Automatic Transmission:
A Mercedes-Benz sourced 5-speed automatic transmission was a prevalent option, offering smooth gear changes and good drivability.
Features
Drivetrain:
Part-time or full-time 4WD systems were offered, often with low-range gearing for enhanced off-road capability. The manual covers servicing and repair for both 2WD and 4WD configurations.
๐Ÿ“ Dimensions
Exterior
Overall Length:
Approximately 4,720 mm (185.8 inches) for most configurations.
Overall Width:
Approximately 1,865 mm (73.4 inches).
Overall Height:
Approximately 1,795 mm (70.7 inches).
Weights
Curb Weight:
Typically ranging from 1,900 kg to 2,100 kg (4,189 lbs to 4,630 lbs) depending on engine and drivetrain.
Towing Capacity:
Generally rated for towing capacities up to 2,000 kg (4,400 lbs) with braked trailers.
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Results:
Specific crash test ratings from independent agencies (like Euro NCAP or NHTSA) for the 2001-2003 Rexton are not widely publicized or may vary by region. However, the vehicle was equipped with standard safety features for its time.
Active Features
ABS:
Anti-lock Braking System (ABS) was typically standard or available.
Traction Control:
Traction control systems may have been available on higher trim levels or as an option.
Passive Features
Airbags:
Front airbags for driver and passenger were standard. Side airbags and curtain shield airbags were available on some models or as options.
Seat Belts:
Three-point seat belts with pre-tensioners for front occupants, and lap or three-point belts for rear occupants. Seat belt warning system is likely included.
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player was common. Higher trims might have offered premium sound systems, navigation (less common for this era), and steering wheel audio controls.
Driver Assistance
Cruise Control:
Cruise control was generally available as standard or an option on most Rexton models.
Connectivity
Auxiliary Ports:
Auxiliary input ports for external audio devices might have been present on later models within this range, but typically not standard on the earliest models.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km (3,000-6,000 miles) or every 6-12 months for diesel engines, depending on driving conditions. The manual will provide precise intervals.
Timing Belt Replacement:
Diesel engines often utilize timing chains which are designed to last the life of the engine, but specific guidance for belt-driven auxiliaries would be in the manual. If a timing belt is present on a gasoline variant, intervals are typically around 80,000-100,000 km (50,000-60,000 miles).
Fluid Specifications
Engine Oil Type:
For diesel engines, a high-quality diesel engine oil meeting API CI-4 or ACEA E5/E7 specifications, typically in viscosity grades like 5W-40 or 10W-40, is recommended. The manual will list specific SsangYong or Mercedes-Benz approvals.
Transmission Fluid:
Automatic transmission fluid type will be specific to the Mercedes-Benz automatic gearbox used (e.g., ATF MB 236.10 or similar). Manual transmission fluid will be a gear oil, likely GL-4 or GL-5 depending on the gearbox.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific color (e.g., green or blue) and type (e.g., OAT or HOAT) will be detailed in the manual.
Known Issues
Common Problems:
Potential issues for this generation can include turbocharger wear (especially on diesel engines with high mileage), EGR valve issues, glow plug problems, and common wear items on suspension and drivetrain components due to its heavy nature and off-road capability. Electronic components related to the ABS and traction control systems might also require attention.
๐Ÿ“š Vehicle History
Brand Heritage
Ssangyong Origin:
SsangYong Motor Company is a South Korean manufacturer, originally established in 1954. It has a history of producing rugged utility vehicles and SUVs, often utilizing technology and components from partner companies like Mercedes-Benz.
Model Evolution
Rexton Development:
The Rexton was SsangYong's flagship SUV, built on a robust chassis inherited from its Musso predecessor, but with a more modern and luxurious design. It aimed to blend passenger car comfort with SUV utility.
Production
Manufacturing Locations:
Primarily manufactured in South Korea by SsangYong Motor Company.
๐Ÿ† Awards & Recognition
Recognitions
Automotive Awards:
Specific prominent awards for the 2001-2003 SsangYong Rexton are not widely documented. The brand's focus was on delivering value and capability in its segment.
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