Ssangyong Rexton Y200 2001-2006 Repair Service Manual
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๐ท๏ธ Basic Information Identification Make: SsangYong Model: Rexton Generation Code: Y200 Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 ๐ Introduction Market Position Positioning: The SsangYong Rexton Y200 positions itself as a capable and rugged SUV, often competing in the mid-size SUV segment with an emphasis on utility and value. Competitive Analysis Competitors: Competed against vehicles like the Hyundai Terracan, Kia Sorento, Mitsubishi Pajero Sport, and similar body-on-frame SUVs of its era. Key Features Strengths: Robust chassis construction, capable off-road performance (especially with 4WD variants), spacious interior, and competitive pricing relative to some European counterparts. Target Audience Audience: Primarily aimed at professional technicians, but also highly beneficial for DIY enthusiasts with a foundational understanding of automotive mechanics and electrical systems. ๐ Manual Details Coverage Areas Primary Coverage: Repair and Service Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: Detailed and comprehensive, likely exceeding 1000 pages (typical for factory service manuals) Manual Type Type: Repair Service Manual / Workshop Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Engine: Detailed coverage including diagnosis, repair, and overhaul of engine components. Specific engine variants expected to be covered. Powertrain: Includes transmission (manual and automatic), transfer case, drive shafts, differentials, and axles. Chassis Suspension: Covers front and rear suspension systems, steering, and related components. Brakes: Comprehensive information on hydraulic brake systems, ABS, parking brake, and component replacement. Electrical System: Extensive coverage of wiring diagrams, electrical components, lighting, starting, charging, and accessory systems. Body And Interior: Information on body panels, doors, windows, interior trim, HVAC system, and related repairs. Heating Ventilation Air Conditioning: Detailed procedures for diagnosing and repairing the HVAC system. Fuel System: Covers fuel injection systems, fuel pumps, injectors, and associated components. Exhaust System: Information on exhaust components, catalytic converters, and emissions control. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, and inspections. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon issues. Repair: Step-by-step repair instructions for all major vehicle systems and components. Disassembly Assembly: Detailed instructions for removing, disassembling, cleaning, inspecting, and reassembling parts. Specifications Data: Crucial technical specifications, torque values, clearances, and diagnostic parameters. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers from basic maintenance to complex diagnostics and major component overhauls. ๐ Manual Specifications File Format Format: PDF Print Quality Printable: Full Printable Zoom Capability Zoom: Zoom IN/OUT enabled Delivery Method Delivery: Instant Download Software Requirements Reader: Adobe PDF Reader Unzipping: WinZip (or equivalent) Compatibility Operating Systems: All Versions of Windows & Mac Manual Attributes Content Type: Includes step-by-step repair procedures, critical specifications, illustrations/pictures, maintenance, disassembly, assembly, cleaning, and reinstalling procedures. โ๏ธ Engine Specifications Primary Engine Engine Options: Likely includes a 2.7L (2696cc) Mercedes-Benz OM662 derived diesel engine (e.g., Rexton I) and potentially a gasoline variant. Specific engine codes and displacements should be confirmed by the manual. Performance Diesel Power Output: Typically around 120-165 PS (90-123 kW) and torque figures in the range of 250-330 Nm, depending on the specific engine variant and tuning. Fuel System Diesel Fuel System: Common Rail Direct Injection (CRDI) for later models, with earlier models potentially using indirect injection or different diesel technologies. Engine Management ECU: Engine Control Unit (ECU) with diagnostic capabilities, requiring specialized scan tools for advanced diagnostics. ๐ง Transmission Standard Transmission Options: Likely offered with both a 5-speed manual transmission and a 5-speed T-Tronic automatic transmission (based on Mercedes-Benz designs). Features Drivetrain: Available in RWD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations, often with selectable or full-time 4WD systems. Fluid Specifications Automatic Transmission Fluid: Specific ATF type required (e.g., MB 236.10 or equivalent) for the automatic transmission. Manual transmission would use GL-4 or GL-5 gear oil. ๐ Dimensions Exterior Length: Approximately 4700-4750 mm (depending on exact variant). Width: Approximately 1870 mm. Height: Approximately 1770 mm. Wheelbase Wheelbase: Approximately 2720 mm. Weights Curb Weight: Ranges typically from 1900 kg to 2100 kg, depending on engine and drivetrain configuration. ๐ก๏ธ Safety Features Ratings Crash Test History: As a vehicle from this era, crash test ratings may vary by region and availability. However, typical safety features would have been incorporated. Active Features ABS: Anti-lock Braking System (ABS) likely standard on most variants. Traction Control: Traction Control System (TCS) and Electronic Stability Program (ESP) may have been optional or standard on higher trims. Passive Features Airbags: Front airbags for driver and passenger are expected. Side airbags might have been available on certain trims. Seatbelts: Three-point seatbelts with pretensioners for front occupants. ๐ก Technology Features Infotainment Audio System: Basic audio systems with CD players and AM/FM radio. Higher trims may have offered upgraded speakers or external CD changers. Navigation: Optional factory-fitted navigation systems were available on some higher-end models, though likely basic by modern standards. Driver Assistance Parking Aids: Rear parking sensors may have been available as an option or on...
The SsangYong Rexton Y200 positions itself as a capable and rugged SUV, often competing in the mid-size SUV segment with an emphasis on utility and value.
Competitive Analysis
Competitors:
Competed against vehicles like the Hyundai Terracan, Kia Sorento, Mitsubishi Pajero Sport, and similar body-on-frame SUVs of its era.
Key Features
Strengths:
Robust chassis construction, capable off-road performance (especially with 4WD variants), spacious interior, and competitive pricing relative to some European counterparts.
Target Audience
Audience:
Primarily aimed at professional technicians, but also highly beneficial for DIY enthusiasts with a foundational understanding of automotive mechanics and electrical systems.
๐ Manual Details
Coverage Areas
Primary Coverage:
Repair and Service
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Page Count:
Detailed and comprehensive, likely exceeding 1000 pages (typical for factory service manuals)
Manual Type
Type:
Repair Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
๐ Manual Coverage
Systems Covered
Engine:
Detailed coverage including diagnosis, repair, and overhaul of engine components. Specific engine variants expected to be covered.
Powertrain:
Includes transmission (manual and automatic), transfer case, drive shafts, differentials, and axles.
Chassis Suspension:
Covers front and rear suspension systems, steering, and related components.
Brakes:
Comprehensive information on hydraulic brake systems, ABS, parking brake, and component replacement.
Electrical System:
Extensive coverage of wiring diagrams, electrical components, lighting, starting, charging, and accessory systems.
Body And Interior:
Information on body panels, doors, windows, interior trim, HVAC system, and related repairs.
Heating Ventilation Air Conditioning:
Detailed procedures for diagnosing and repairing the HVAC system.
Fuel System:
Covers fuel injection systems, fuel pumps, injectors, and associated components.
Exhaust System:
Information on exhaust components, catalytic converters, and emissions control.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, and inspections.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues.
Repair:
Step-by-step repair instructions for all major vehicle systems and components.
Disassembly Assembly:
Detailed instructions for removing, disassembling, cleaning, inspecting, and reassembling parts.
Specifications Data:
Crucial technical specifications, torque values, clearances, and diagnostic parameters.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers from basic maintenance to complex diagnostics and major component overhauls.
๐ Manual Specifications
File Format
Format:
PDF
Print Quality
Printable:
Full Printable
Zoom Capability
Zoom:
Zoom IN/OUT enabled
Delivery Method
Delivery:
Instant Download
Software Requirements
Reader:
Adobe PDF Reader
Unzipping:
WinZip (or equivalent)
Compatibility
Operating Systems:
All Versions of Windows & Mac
Manual Attributes
Content Type:
Includes step-by-step repair procedures, critical specifications, illustrations/pictures, maintenance, disassembly, assembly, cleaning, and reinstalling procedures.
โ๏ธ Engine Specifications
Primary Engine
Engine Options:
Likely includes a 2.7L (2696cc) Mercedes-Benz OM662 derived diesel engine (e.g., Rexton I) and potentially a gasoline variant. Specific engine codes and displacements should be confirmed by the manual.
Performance
Diesel Power Output:
Typically around 120-165 PS (90-123 kW) and torque figures in the range of 250-330 Nm, depending on the specific engine variant and tuning.
Fuel System
Diesel Fuel System:
Common Rail Direct Injection (CRDI) for later models, with earlier models potentially using indirect injection or different diesel technologies.
Engine Management
ECU:
Engine Control Unit (ECU) with diagnostic capabilities, requiring specialized scan tools for advanced diagnostics.
๐ง Transmission
Standard
Transmission Options:
Likely offered with both a 5-speed manual transmission and a 5-speed T-Tronic automatic transmission (based on Mercedes-Benz designs).
Features
Drivetrain:
Available in RWD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations, often with selectable or full-time 4WD systems.
Fluid Specifications
Automatic Transmission Fluid:
Specific ATF type required (e.g., MB 236.10 or equivalent) for the automatic transmission. Manual transmission would use GL-4 or GL-5 gear oil.
๐ Dimensions
Exterior
Length:
Approximately 4700-4750 mm (depending on exact variant).
Width:
Approximately 1870 mm.
Height:
Approximately 1770 mm.
Wheelbase
Wheelbase:
Approximately 2720 mm.
Weights
Curb Weight:
Ranges typically from 1900 kg to 2100 kg, depending on engine and drivetrain configuration.
๐ก๏ธ Safety Features
Ratings
Crash Test History:
As a vehicle from this era, crash test ratings may vary by region and availability. However, typical safety features would have been incorporated.
Active Features
ABS:
Anti-lock Braking System (ABS) likely standard on most variants.
Traction Control:
Traction Control System (TCS) and Electronic Stability Program (ESP) may have been optional or standard on higher trims.
Passive Features
Airbags:
Front airbags for driver and passenger are expected. Side airbags might have been available on certain trims.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
๐ก Technology Features
Infotainment
Audio System:
Basic audio systems with CD players and AM/FM radio. Higher trims may have offered upgraded speakers or external CD changers.
Navigation:
Optional factory-fitted navigation systems were available on some higher-end models, though likely basic by modern standards.
Driver Assistance
Parking Aids:
Rear parking sensors may have been available as an option or on higher trim levels.
Connectivity
Auxiliary Inputs:
Limited connectivity options; auxiliary audio inputs were not common, and Bluetooth integration was rare for this period.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000 to 15,000 km) or 6-12 months, depending on driving conditions and specific engine variant. The manual will provide exact intervals.
Timing Belt Interval:
If equipped with a timing belt, replacement is critical, usually around 60,000 to 100,000 miles (100,000 to 160,000 km). The manual will specify belt or chain and respective intervals.
Fluid Specifications
Engine Oil Type:
Depends on engine variant. Diesel engines often require API CI-4 or CH-4 specifications, with viscosities like 5W-40 or 15W-40. Gasoline engines would have different requirements. Refer to manual for exact specifications and API ratings.
Coolant Type:
Ethylene glycol-based coolant, typically a long-life or OAT (Organic Acid Technology) type. Manual will specify color and type (e.g., G12/G12+).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid is standard. Manual will specify the required type and change interval.
Known Issues
Common Wear Items:
Potential for worn suspension components (bushings, ball joints), early wear on turbochargers (diesel variants), and common electrical gremlins (e.g., sensors, wiring harnesses) typical for vehicles of this age.
Diesel Specific Concerns:
Glow plugs, injection pump seals, and turbocharger durability can be points of concern on older diesel engines. EGR system can also be a source of issues.
Rust Corrosion:
As with many SUVs of this era, particularly those in regions with harsh winters, rust and corrosion on the frame, body panels, and exhaust system can be an issue.
๐ Vehicle History
Brand Heritage
Origins:
SsangYong Motor Company is a South Korean manufacturer known for its SUVs and commercial vehicles. It has had periods of ownership by Daewoo, SAAB, and Mahindra & Mahindra.
Model Evolution
Development:
The Rexton Y200 was SsangYong's flagship SUV, built on a robust body-on-frame chassis, showcasing their capability in developing larger, more rugged vehicles, often leveraging Mercedes-Benz technology, particularly in powertrains.
Production
Manufacturing Location:
Primarily manufactured in South Korea.
๐ Awards & Recognition
Recognitions
Awards History:
Specific prominent awards for the Rexton Y200 are not widely documented in major international automotive publications, but it was recognized for its value and ruggedness in certain markets.