2006 SsangYong Rodius A120 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rodius Year: 2006 Product Name: 2006 SsangYong Rodius A120 Service Repair Workshop Manual Codes Chassis Code: A120 👋 Introduction Market Position Vehicle Type: Full-size MPV (Multi-Purpose Vehicle) / SUV-like MPV Segment Positioning: SsangYong's attempt to offer a spacious and versatile people carrier with a distinctive, if polarizing, design. Competitive Analysis Competitors: Kia Carnival, Hyundai Starex, potentially some larger minivan and SUV offerings depending on market. Key Features Design Philosophy: Focus on maximizing interior space and passenger comfort, with a bold and somewhat unconventional exterior styling. Interior Versatility: Multiple seating configurations to accommodate up to seven or more passengers, with ample cargo space. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Drivetrain: Yes Brakes: Yes Suspension: Yes Steering: Yes Electrical System: Yes Body And Chassis: Yes Heating Ventilation Air Conditioning HVAC: Yes Interior Appointments: Yes Diagnostics And Troubleshooting: Yes Maintenance Schedules: Yes Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures for engine block, cylinder head, pistons, crankshaft, camshaft, timing system, lubrication system. Engine Management: Fuel injection system (DI, Common Rail), ignition system, emissions control systems, engine control unit (ECU) diagnosis. Transmission Manual: Service and repair of the manual gearbox, clutch operation, and related components. Transmission Automatic: If equipped, detailed service and repair for the automatic transmission, torque converter, valve body, and electronic controls. Drivetrain: Front-wheel drive (FWD) and rear-wheel drive (RWD) system components, driveshafts, differentials, hub assemblies. Suspension Front: MacPherson strut, coil springs, shock absorbers, control arms, anti-roll bar, wheel bearing replacement. Suspension Rear: Multi-link suspension, coil springs, shock absorbers, control arms, anti-roll bar, axle components. Steering System: Power steering system components, steering rack, pump, fluid, linkages, alignment procedures. Brake System: Front and rear disc brakes, hydraulic system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake pad and rotor replacement, fluid flush. Electrical System Lighting: Headlights, taillights, interior lighting, fog lights, bulb replacement, wiring diagrams. Electrical System Charging: Alternator, battery, charging system diagnosis. Electrical System Starting: Starter motor, ignition switch, starting system diagnosis. Body And Exterior: Door mechanisms, hinges, latches, bumpers, body panels, glass replacement, trim. Interior And Comfort: Seats, dashboard, console, door panels, upholstery, headliner, accessory installation. HVAC System: Air conditioning compressor, condenser, evaporator, blower motor, climate control unit, refrigerant handling, cabin air filter. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, belt inspections. Major Repairs: Engine rebuilds, transmission overhauls, differential rebuilds, suspension component replacement. Diagnostics: Systematic troubleshooting guides for common and uncommon problems, symptom-based diagnosis. Wiring Diagrams: Comprehensive electrical schematics for all major systems, including power distribution, lighting, ignition, and sensor circuits. Torque Specifications: Precise torque values for all critical fasteners and bolts throughout the vehicle. Tightening Sequences: Correct order and sequence for tightening critical components like cylinder heads and wheel lugs. Component Removal And Installation: Step-by-step instructions for removing and installing virtually every component. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth: Covers everything from basic maintenance and fluid changes to complete engine and transmission overhauls, complex electrical diagnostics, and bodywork repairs. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Diagram Quality: High-quality, clear, and detailed diagrams and illustrations. Text Readability: Easy-to-read text sections. Binding Type Binding: Digital (PDF - no physical binding) Paper Type Paper: Digital (PDF - no physical paper) ⚙️ Engine Specifications Primary Engine Engine Type: Diesel Engine Displacement: 2.7 Liters (2696 cc) Engine Code Common: XDi270 (Mercedes-Benz OM664 derivative) Cylinders: 5 Cylinder (Inline) Aspiration: Turbocharged, Intercooled Performance Horsepower Ps: 165 PS @ 4000 RPM (approximate) Torque Nm: 340 Nm @ 1800-3000 RPM (approximate) Fuel System Fuel Injection: Common Rail Direct Injection (CRDi) Emission Control: Euro 3/4 compliant (depending on market), EGR system. 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 5-Speed Automatic Transmission Features Drive Layout: Rear-Wheel Drive (RWD) or Part-time Four-Wheel Drive (4WD) Automatic Transmission Control: Electronic control with adaptive shift logic. 📐 Dimensions Exterior Length Mm: 4770 - 4930 (depending on configuration) Width Mm: 1900 Height Mm: 1750 - 1800 (depending on configuration) Wheelbase Mm: 2755 - 2870 (depending on configuration) Weights Curb Weight Kg: 1950 - 2150 (approximate, depending on configuration) Gross Vehicle Weight Rating Gvwr Kg: 2700 - 2800 (approximate) 🛡️ Safety Features Ratings E Ncap Rating: Not extensively tested or rated by major organizations like Euro NCAP for this specific model year/region. Typically perceived as basic for its era. Active Features ABS: Standard Ebd: Standard (Electronic Brakeforce Distribution) Traction Control TCS: Optional on some trims/markets. Electronic Stability Program Esp: Optional on some trims/markets. Passive Features Airbags Front: Driver and front passenger airbags standard. Airbags Side: Optional front side airbags, optional...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rodius

Year:

Product Name:

2006 SsangYong Rodius A120 Service Repair Workshop Manual

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Type:

Full-size MPV (Multi-Purpose Vehicle) / SUV-like MPV

Segment Positioning:

SsangYong's attempt to offer a spacious and versatile people carrier with a distinctive, if polarizing, design.

Competitive Analysis

Competitors:

Kia Carnival, Hyundai Starex, potentially some larger minivan and SUV offerings depending on market.

Key Features

Design Philosophy:

Focus on maximizing interior space and passenger comfort, with a bold and somewhat unconventional exterior styling.

Interior Versatility:

Multiple seating configurations to accommodate up to seven or more passengers, with ample cargo space.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Brakes:

Suspension:

Steering:

Electrical System:

Body And Chassis:

Heating Ventilation Air Conditioning HVAC:

Interior Appointments:

Diagnostics And Troubleshooting:

Maintenance Schedules:

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures for engine block, cylinder head, pistons, crankshaft, camshaft, timing system, lubrication system.

Engine Management:

Fuel injection system (DI, Common Rail), ignition system, emissions control systems, engine control unit (ECU) diagnosis.

Transmission Manual:

Service and repair of the manual gearbox, clutch operation, and related components.

Transmission Automatic:

If equipped, detailed service and repair for the automatic transmission, torque converter, valve body, and electronic controls.

Drivetrain:

Front-wheel drive (FWD) and rear-wheel drive (RWD) system components, driveshafts, differentials, hub assemblies.

Suspension Front:

MacPherson strut, coil springs, shock absorbers, control arms, anti-roll bar, wheel bearing replacement.

Suspension Rear:

Multi-link suspension, coil springs, shock absorbers, control arms, anti-roll bar, axle components.

Steering System:

Power steering system components, steering rack, pump, fluid, linkages, alignment procedures.

Brake System:

Front and rear disc brakes, hydraulic system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake pad and rotor replacement, fluid flush.

Electrical System Lighting:

Headlights, taillights, interior lighting, fog lights, bulb replacement, wiring diagrams.

Electrical System Charging:

Alternator, battery, charging system diagnosis.

Electrical System Starting:

Starter motor, ignition switch, starting system diagnosis.

Body And Exterior:

Door mechanisms, hinges, latches, bumpers, body panels, glass replacement, trim.

Interior And Comfort:

Seats, dashboard, console, door panels, upholstery, headliner, accessory installation.

HVAC System:

Air conditioning compressor, condenser, evaporator, blower motor, climate control unit, refrigerant handling, cabin air filter.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, belt inspections.

Major Repairs:

Engine rebuilds, transmission overhauls, differential rebuilds, suspension component replacement.

Diagnostics:

Systematic troubleshooting guides for common and uncommon problems, symptom-based diagnosis.

Wiring Diagrams:

Comprehensive electrical schematics for all major systems, including power distribution, lighting, ignition, and sensor circuits.

Torque Specifications:

Precise torque values for all critical fasteners and bolts throughout the vehicle.

Tightening Sequences:

Correct order and sequence for tightening critical components like cylinder heads and wheel lugs.

Component Removal And Installation:

Step-by-step instructions for removing and installing virtually every component.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Covers everything from basic maintenance and fluid changes to complete engine and transmission overhauls, complex electrical diagnostics, and bodywork repairs.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Diagram Quality:

High-quality, clear, and detailed diagrams and illustrations.

Text Readability:

Easy-to-read text sections.

Binding Type

Binding:

Digital (PDF - no physical binding)

Paper Type

Paper:

Digital (PDF - no physical paper)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Diesel Engine

Displacement:

2.7 Liters (2696 cc)

Engine Code Common:

XDi270 (Mercedes-Benz OM664 derivative)

Cylinders:

5 Cylinder (Inline)

Aspiration:

Turbocharged, Intercooled

Performance

Horsepower Ps:

165 PS @ 4000 RPM (approximate)

Torque Nm:

340 Nm @ 1800-3000 RPM (approximate)

Fuel System

Fuel Injection:

Common Rail Direct Injection (CRDi)

Emission Control:

Euro 3/4 compliant (depending on market), EGR system.

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

5-Speed Automatic Transmission

Features

Drive Layout:

Rear-Wheel Drive (RWD) or Part-time Four-Wheel Drive (4WD)

Automatic Transmission Control:

Electronic control with adaptive shift logic.

📐 Dimensions

Exterior

Length Mm:

4770 - 4930 (depending on configuration)

Width Mm:

Height Mm:

1750 - 1800 (depending on configuration)

Wheelbase Mm:

2755 - 2870 (depending on configuration)

Weights

Curb Weight Kg:

1950 - 2150 (approximate, depending on configuration)

Gross Vehicle Weight Rating Gvwr Kg:

2700 - 2800 (approximate)

🛡️ Safety Features

Ratings

E Ncap Rating:

Not extensively tested or rated by major organizations like Euro NCAP for this specific model year/region. Typically perceived as basic for its era.

Active Features

Standard

Standard (Electronic Brakeforce Distribution)

Traction Control TCS:

Optional on some trims/markets.

Electronic Stability Program Esp:

Optional on some trims/markets.

Passive Features

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side:

Optional front side airbags, optional curtain airbags on higher trims.

Seatbelts:

Three-point seatbelts with pretensioners for front seats; three-point seatbelts for rear seats.

Child Seat Anchors:

ISOFIX/LATCH child seat mounting points in rear seating positions.

💡 Technology Features

Infotainment

Head Unit:

Basic single-DIN or double-DIN radio/CD player, possibly with auxiliary input. Higher trims might have integrated CD changers or early navigation systems.

Speaker System:

Standard 4-6 speaker setup. Premium audio systems were rare.

Driver Assistance

Cruise Control:

Available on higher trims.

Parking Sensors:

Optional rear parking sensors on some models.

Connectivity

Bluetooth:

Very limited or non-existent on base models. Aftermarket solutions common.

Usb Aux:

Auxiliary input socket often available. USB ports were uncommon for this era.

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 7,500 to 10,000 miles (12,000 to 15,000 km) or 12 months, whichever comes first. Refer to manual for specific intervals based on driving conditions.

Air Filter Replacement:

Every 15,000 to 20,000 miles (24,000 to 32,000 km).

Fuel Filter Replacement:

Every 20,000 to 30,000 miles (32,000 to 48,000 km) for diesel engines.

Coolant Replacement:

Initial replacement at 5 years or 100,000 miles, then every 2-3 years or 30,000-50,000 miles.

Transmission Fluid Change Automatic:

Every 30,000 to 50,000 miles (48,000 to 80,000 km), depending on usage. Fluid flush recommended.

Transmission Fluid Change Manual:

Every 40,000 to 60,000 miles (64,000 to 96,000 km).

Fluid Specifications

Engine Oil Grade:

API CI-4 or higher, SAE 5W-30 or 5W-40 fully synthetic diesel engine oil recommended (verify specific viscosity based on ambient temperature).

Engine Oil Capacity Liters:

Approximately 7.5 - 8.0 liters (with filter).

Coolant Type:

Ethylene glycol based coolant with long-life additives (e.g., G11 or G12 equivalent).

Automatic Transmission Fluid Atf Type:

Mercedes-Benz spec fluid (e.g., MB 236.10 or compatible equivalent).

Manual Transmission Fluid Type:

GL-4 or GL-5 SAE 75W-90 gear oil.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Hydraulic fluid meeting specific SsangYong/Mercedes-Benz specifications (e.g., MB 236.3 or equivalent).

Known Issues

Common Diesel Engine Issues:

Potential for injector issues, EGR valve clogging, turbocharger wear, glow plug failures, and swirl flap issues (if applicable).

Common Transmission Issues:

Automatic transmission might exhibit delayed shifting or rough engagement; manual clutch wear.

Common Suspension Issues:

Wear on bushings, ball joints, and tie rod ends due to vehicle weight and usage; occasional shock absorber leaks.

Common Electrical Issues:

Faulty sensors (e.g., crankshaft/camshaft position sensors), issues with the central locking or alarm system, corroded wiring connectors.

Body And Interior Issues:

Rust formation on the body panels (especially in corrosive environments), interior trim rattles, potential for AC system leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

SsangYong Motor Company, South Korea.

Brand Focus:

Historically known for SUVs and trucks, often utilizing Mercedes-Benz technology and powertrains.

Model Evolution

Introduction Year:

Design Influence:

Shares powertrain and chassis elements with other SsangYong models of the era, often utilizing Mercedes-Benz licensed technology.

Design Criticism:

Exterior styling is frequently cited as unusual or polarizing.

Production

Production Period:

2005-2012 (First Generation)

Manufacturing Location:

South Korea

🏆 Awards & Recognition

Recognitions

Major Awards:

No significant industry awards or widespread critical acclaim recognized for this model, primarily due to its niche market appeal and polarizing design.

Ratings

Reliability Index:

Generally considered average to below average compared to mainstream competitors, with a higher propensity for electrical and diesel-specific issues if not properly maintained.