Ssangyong Rexton 290TD Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Model Variant: 290TD Vehicle Type: SUV Generation Generation: First Generation (Y200/Y250) Codes Chassis Code: Y200/Y250 👋 Introduction Market Position Market Position: The SsangYong Rexton 290TD, particularly in its early generations, positioned itself as a robust and capable large SUV, often with a focus on utility and off-road prowess at a competitive price point. It aimed to compete in segments with established players, offering a value proposition. Competitive Analysis Competitors: During its production run, the Rexton 290TD would have competed with vehicles like the Mitsubishi Pajero/Montero, Toyota Land Cruiser Prado, Land Rover Discovery, and similarly sized SUVs from various manufacturers, depending on regional markets. Key Features Key Features: The 290TD variant is characterized by its turbodiesel engine, body-on-frame construction (common in robust SUVs), and substantial interior space. It typically offered selectable four-wheel drive, a commanding driving position, and good towing capacity, making it a practical choice for families and those with recreational needs. Manual Utility Manual Utility: This manual is an essential tool for owners and independent mechanics seeking to maintain, diagnose, and repair the SsangYong Rexton 290TD, ensuring it operates at optimal factory settings. Its comprehensive nature aims to reduce reliance on costly dealership services. 📋 Manual Details Coverage Areas Systems Covered Overview: Engine Mechanical, Lubrication, Cooling, Control, Fuel, Exhaust, Transmission (Manual & Automatic), Driveline, Axles, Suspension, Brakes, Steering, Restraints (Seat belts & SRS), Body, Locks, Security, Glass, Mirrors, Interior, Exterior, Air Conditioning, Electrical Systems (Wiring, Starting/Charging, Lighting, Information Displays, Wipers/Washers/Horns, Body Control, LAN, Audio/Visual, Navigation, Telephone, Cruise Control, Power Supply/Grounds/Circuits), and General Maintenance. Page Count Estimated Page Count: Detailed page count not specified, but comprehensive coverage implies a significant volume. Manual Type Manual Type: Service and Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical components, lubrication system (oil pump, filter, passages), cooling system (radiator, thermostat, water pump, coolant), engine control system (ECU, sensors, actuators, diagnostics), fuel system (injectors, fuel pump, filters, rail pressure), and exhaust system (manifold, catalytic converter, muffler). Transmission Systems: Clutch system (operation, adjustments, replacement), Manual Transaxle (gearbox operation, internal components, lubrication, repair), and Automatic Transaxle (torque converter, valve body, internal gears, electronic controls, fluid service). Drivetrain And Suspension: Front axle (CV joints, differentials), Rear axle (housing, gears, differentials), Front Suspension (control arms, springs, shock absorbers, bushings), Rear Suspension (multi-link, springs, shock absorbers), and Road Wheels & Tires (selection, mounting, balancing, rotation). Braking And Steering: Brake System (disc/drum operation, hydraulic components, calipers, master cylinder, ABS), Parking Brake System (mechanism, cables), Brake Control System (ABS, EBD), Power Steering System (pump, rack and pinion, hoses), and Steering System (column, linkages, alignment). Safety And Body: Seat Belts (pre-tensioners, retractors), Supplemental Restraint System (SRS - airbags, control module, sensors), Body (structural components, panels), Locks & Security System (central locking, alarm), Glasses, Window System & Mirrors (operation, replacement), Roof (sunroof, seals), Exterior & Interior trim, Instrument Panel (gauges, warning lights), and Seats (adjustment mechanisms, upholstery). Climate Control And Electrical: Air Conditioner System (compressor, refrigerant, controls, diagnosis), Electrical Wiring Diagrams (comprehensive schematics), Starting & Charging System (alternator, starter motor, battery), Lighting System (headlights, taillights, interior lighting), Driver Information System (displays, alerts), Wiper, Washer & Horn, Body Control System (modules, actuators), LAN System (CAN bus communication), Audio Visual, Navigation & Telephone System, Auto Cruise Control System, and Power Supply, Ground & Circuit Elements. Procedures Included Maintenance Procedures: Scheduled maintenance (oil changes, filter replacements, fluid checks), brake servicing (pad/rotor replacement, bleeding), suspension component replacement, belt and hose inspection/replacement, air conditioning servicing, battery testing, tire rotation, and general inspections. Diagnostic And Repair Procedures: Engine diagnosis, fuel system troubleshooting, cooling system repair, transmission repair (manual and automatic), brake system repair, steering system repair, electrical system diagnosis, wiring harness repair, SRS system diagnostics, bodywork repair, and HVAC system troubleshooting. Technical Depth Technical Depth: Comprehensive, covering from basic maintenance tasks to advanced diagnostic and repair procedures for all major systems. Includes detailed explanations of how systems work, troubleshooting guides, and step-by-step repair instructions with diagrams. 📊 Manual Specifications File Format File Format: PDF Print Quality Printable: All pages are printable. Binding Type Binding Type: Digital (PDF) - implies no physical binding. Paper Type Paper Type: Not applicable for digital format. Software Requirements Software Requirements: Adobe PDF Reader and WinZip (for potential archive extraction). ⚙️ Engine Specifications Primary Engine Engine Model: OM662LA (Mercedes-Benz derived turbodiesel) Engine Type: Inline 5-cylinder Turbodiesel Displacement: 2.9 Liters (2874 cc) Performance Horsepower: Approximately 120-130 HP (exact figures vary by market and specific tuning) Torque: Approximately 250-260 Nm (exact figures vary by market and specific tuning) Fuel System Fuel Type: Diesel Fuel Delivery: Indirect Injection with Turbocharging and Intercooling Cooling System Coolant Type: Ethylene Glycol based coolant (specific SsangYong or equivalent specification recommended) Lubrication System Engine Oil Type: API CF or higher, SAE 15W-40 or 10W-40 (depending on...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton

Model Variant:

290TD

Vehicle Type:

Generation

Generation:

First Generation (Y200/Y250)

Codes

Chassis Code:

Y200/Y250

👋 Introduction

Market Position

Market Position:

The SsangYong Rexton 290TD, particularly in its early generations, positioned itself as a robust and capable large SUV, often with a focus on utility and off-road prowess at a competitive price point. It aimed to compete in segments with established players, offering a value proposition.

Competitive Analysis

Competitors:

During its production run, the Rexton 290TD would have competed with vehicles like the Mitsubishi Pajero/Montero, Toyota Land Cruiser Prado, Land Rover Discovery, and similarly sized SUVs from various manufacturers, depending on regional markets.

Key Features

Key Features:

The 290TD variant is characterized by its turbodiesel engine, body-on-frame construction (common in robust SUVs), and substantial interior space. It typically offered selectable four-wheel drive, a commanding driving position, and good towing capacity, making it a practical choice for families and those with recreational needs.

Manual Utility

Manual Utility:

This manual is an essential tool for owners and independent mechanics seeking to maintain, diagnose, and repair the SsangYong Rexton 290TD, ensuring it operates at optimal factory settings. Its comprehensive nature aims to reduce reliance on costly dealership services.

📋 Manual Details

Coverage Areas

Systems Covered Overview:

Engine Mechanical, Lubrication, Cooling, Control, Fuel, Exhaust, Transmission (Manual & Automatic), Driveline, Axles, Suspension, Brakes, Steering, Restraints (Seat belts & SRS), Body, Locks, Security, Glass, Mirrors, Interior, Exterior, Air Conditioning, Electrical Systems (Wiring, Starting/Charging, Lighting, Information Displays, Wipers/Washers/Horns, Body Control, LAN, Audio/Visual, Navigation, Telephone, Cruise Control, Power Supply/Grounds/Circuits), and General Maintenance.

Page Count

Estimated Page Count:

Detailed page count not specified, but comprehensive coverage implies a significant volume.

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical components, lubrication system (oil pump, filter, passages), cooling system (radiator, thermostat, water pump, coolant), engine control system (ECU, sensors, actuators, diagnostics), fuel system (injectors, fuel pump, filters, rail pressure), and exhaust system (manifold, catalytic converter, muffler).

Transmission Systems:

Clutch system (operation, adjustments, replacement), Manual Transaxle (gearbox operation, internal components, lubrication, repair), and Automatic Transaxle (torque converter, valve body, internal gears, electronic controls, fluid service).

Drivetrain And Suspension:

Front axle (CV joints, differentials), Rear axle (housing, gears, differentials), Front Suspension (control arms, springs, shock absorbers, bushings), Rear Suspension (multi-link, springs, shock absorbers), and Road Wheels & Tires (selection, mounting, balancing, rotation).

Braking And Steering:

Brake System (disc/drum operation, hydraulic components, calipers, master cylinder, ABS), Parking Brake System (mechanism, cables), Brake Control System (ABS, EBD), Power Steering System (pump, rack and pinion, hoses), and Steering System (column, linkages, alignment).

Safety And Body:

Seat Belts (pre-tensioners, retractors), Supplemental Restraint System (SRS - airbags, control module, sensors), Body (structural components, panels), Locks & Security System (central locking, alarm), Glasses, Window System & Mirrors (operation, replacement), Roof (sunroof, seals), Exterior & Interior trim, Instrument Panel (gauges, warning lights), and Seats (adjustment mechanisms, upholstery).

Climate Control And Electrical:

Air Conditioner System (compressor, refrigerant, controls, diagnosis), Electrical Wiring Diagrams (comprehensive schematics), Starting & Charging System (alternator, starter motor, battery), Lighting System (headlights, taillights, interior lighting), Driver Information System (displays, alerts), Wiper, Washer & Horn, Body Control System (modules, actuators), LAN System (CAN bus communication), Audio Visual, Navigation & Telephone System, Auto Cruise Control System, and Power Supply, Ground & Circuit Elements.

Procedures Included

Maintenance Procedures:

Scheduled maintenance (oil changes, filter replacements, fluid checks), brake servicing (pad/rotor replacement, bleeding), suspension component replacement, belt and hose inspection/replacement, air conditioning servicing, battery testing, tire rotation, and general inspections.

Diagnostic And Repair Procedures:

Engine diagnosis, fuel system troubleshooting, cooling system repair, transmission repair (manual and automatic), brake system repair, steering system repair, electrical system diagnosis, wiring harness repair, SRS system diagnostics, bodywork repair, and HVAC system troubleshooting.

Technical Depth

Technical Depth:

Comprehensive, covering from basic maintenance tasks to advanced diagnostic and repair procedures for all major systems. Includes detailed explanations of how systems work, troubleshooting guides, and step-by-step repair instructions with diagrams.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printable:

All pages are printable.

Binding Type

Binding Type:

Digital (PDF) - implies no physical binding.

Paper Type

Paper Type:

Not applicable for digital format.

Software Requirements

Software Requirements:

Adobe PDF Reader and WinZip (for potential archive extraction).

⚙️ Engine Specifications

Primary Engine

Engine Model:

OM662LA (Mercedes-Benz derived turbodiesel)

Engine Type:

Inline 5-cylinder Turbodiesel

Displacement:

2.9 Liters (2874 cc)

Performance

Horsepower:

Approximately 120-130 HP (exact figures vary by market and specific tuning)

Torque:

Approximately 250-260 Nm (exact figures vary by market and specific tuning)

Fuel System

Fuel Type:

Diesel

Fuel Delivery:

Indirect Injection with Turbocharging and Intercooling

Cooling System

Coolant Type:

Ethylene Glycol based coolant (specific SsangYong or equivalent specification recommended)

Lubrication System

Engine Oil Type:

API CF or higher, SAE 15W-40 or 10W-40 (depending on climate) - specific SsangYong approval recommended.

🔧 Transmission

Standard

Transmission Type:

Likely a 5-speed Manual Transmission as standard or a primary option, possibly with a 4-speed Automatic Transmission as an option.

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (e.g., Mercedes-Benz sourced)

Features

Drivetrain:

Selectable 4WD with low-range gearing (part-time 4x4 system is common).

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check manual for exact spec)

Automatic Transmission Fluid:

Dexron III or Mercon equivalent (check manual for exact spec, likely a Dexron type)

📐 Dimensions

Exterior

Length:

Approximately 4700-4730 mm

Width:

Approximately 1870-1880 mm

Height:

Approximately 1770-1800 mm

Weights

Curb Weight:

Approximately 1900-2100 kg (depending on configuration)

Gross Vehicle Weight Rating:

Varies by configuration, but typically around 2600-2700 kg.

Towing Capacity:

Typically rated around 2500-3000 kg (braked towing capacity).

🛡️ Safety Features

Ratings

Crash Test Ratings:

Specific official crash test ratings for early Rexton models may vary by region and testing authority. It's advisable to consult regional safety databases if available.

Active Features

Anti-lock Braking System (ABS) typically standard.

Electronic Brakeforce Distribution (EBD) often integrated with ABS.

Passive Features

Airbags:

Front airbags for driver and passenger are typically standard. Side airbags may be optional depending on trim level and model year.

Seatbelts:

Three-point seatbelts with pre-tensioners for front occupants and rear passengers. ISOFIX child seat mounting points.

💡 Technology Features

Infotainment

Infotainment System:

Early models likely featured a basic AM/FM radio with CD player. Higher trims may have offered more advanced audio systems with cassette players or early CD changers. Navigation systems were likely optional or unavailable on base models.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. ABS was a key safety technology. Features like traction control or stability control were less common or optional on early models.

Connectivity

Connectivity Options:

Basic connectivity for audio systems. Telephone integration would likely be an aftermarket accessory or a very early hands-free option on later models of the first generation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 km or 6-12 months, whichever comes first. Consult manual for specific diesel engine requirements.

Air Filter Replacement:

Recommended every 20,000-30,000 km or annually.

Fuel Filter Replacement:

Crucial for diesel engines. Typically every 30,000-40,000 km. Contaminated fuel can severely damage the injection system.

Timing Belt Replacement:

This engine utilizes a timing chain, not a belt, which generally has a longer service life and is less prone to catastrophic failure. However, periodic checks for wear and noise are recommended.

Fluid Specifications

Coolant Capacity:

Approximately 9-10 liters. Use the correct type of coolant.

Brake Fluid Type:

DOT 3 or DOT 4. Always use fresh fluid from a sealed container.

Known Issues

Common Issues Engine:

Turbocharger issues (wear and tear), glow plug failures, diesel injector problems due to fuel quality, EGR valve clogging. The OM662LA is generally robust but requires proper maintenance.

Common Issues Transmission:

Automatic transmission clutch pack wear, torque converter issues. Manual transmissions are generally durable but clutch wear is a consumable.

Common Issues Suspension And Body:

Bushings and ball joints in suspension can wear over time, leading to clunking noises. Rust can be an issue in certain climates, especially around the body panels and chassis. Electrical gremlins can occur due to wiring age.

📚 Vehicle History

Brand Heritage

Brand Heritage:

SsangYong Motor Company, established in 1954, has a history of producing vehicles, often with a focus on SUVs and commercial vehicles. The brand has experienced periods of ownership by different entities, including Daewoo, SAAB, and Mahindra & Mahindra, impacting its development and market presence.

Model Evolution

Model Evolution:

The Rexton was introduced in 2001 as SsangYong's flagship SUV, designed to be a modern and capable vehicle. It featured a design influenced by Mercedes-Benz technology (due to SsangYong's past ties), particularly in its powertrains and chassis. The 290TD variant utilized the well-regarded Mercedes-Benz OM662LA 2.9L turbodiesel engine.

Production

Production Years For 290Td:

The 290TD variant was part of the first generation Rexton, produced roughly from 2001 until around 2006, before updates led to different engine options.

🏆 Awards & Recognition

Recognitions

Awards And Recognitions:

Specific awards for the Rexton 290TD are not widely publicized. However, SsangYong vehicles have received recognition for their value proposition and capability in certain markets, particularly in the SUV and off-road segments.