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SsangYong Rexton Y250 2006-2008 Service Repair Workshop Manual Pdf

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Model Code: Y250 Model Years Covered: 2006, 2007, 2008 👋 Introduction Market Position Vehicle Class: Body-on-frame SUV, often marketed as a capable and rugged utility vehicle. Competitive Analysis Direct Competitors 2006-2008: SsangYong Rexton competed against SUVs like the Kia Sorento, Hyundai Santa Fe (earlier generations), Mitsubishi Pajero/Montero Sport, and Ford Everest (depending on market). Key Features Vehicle Body Style: Full-size SUV with a strong emphasis on utility and off-road capability. Powertrain Layout: Typically rear-wheel drive (RWD) with optional four-wheel drive (4WD) selectable systems, common for its class. Key Features Manual Manual Value Proposition: Comprehensive factory-level information for DIY repairs and professional workshop use, offering significant cost savings over dealership service. 📋 Manual Details Coverage Areas Geographical Coverage: Global (typical for factory manuals, specific regional variations may exist but not detailed in product info) Market Coverage: All markets where the Rexton Y250 was sold Page Count Estimated Page Count: Hundreds (as stated in description) Manual Type Manual Type: Service Repair Workshop Manual Language Language: Likely English, typical for factory service manuals targeting international markets. Regional language versions are not specified. Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed information on engine disassembly, assembly, diagnostics, and repair for all variants offered in the Y250 generation. Engine Control System: Wiring diagrams, sensor locations, diagnostic trouble codes (DTCs), and troubleshooting for the Engine Control Unit (ECU). Fuel System: Fuel injection system diagnosis, pump, injectors, fuel filter replacement, and pressure testing. Cooling System: Radiator, thermostat, water pump, fan clutch, hoses, and coolant specifications. Lubrication System: Oil pump, oil filter, oil pan, oil specifications, and oil change procedures. Exhaust System: Catalytic converter, muffler, exhaust pipes, and oxygen sensors. Transmission Manual: Diagnosis, repair, and overhaul procedures for manual transmissions, including clutch service. Transmission Automatic: Diagnosis, repair, and overhaul procedures for automatic transmissions, including fluid checks and changes, torque converter service. Drivetrain Transfer Case: Service and repair of the transfer case, including 4WD system operation and maintenance. Drivetrain Axles: Front and rear axle service, differential repair, and driveshaft maintenance. Suspension Front: Struts, control arms, ball joints, tie rod ends, wheel bearings, and alignment specifications. Suspension Rear: Shock absorbers, springs, control arms, bushings, and alignment specifications. Steering System: Power steering pump, rack and pinion, steering column, and associated components. Brake System Front: Disc brake components, calipers, pads, rotors, and hydraulic lines. Brake System Rear: Disc or drum brake components, calipers/wheel cylinders, pads/shoes, rotors/drums, and hydraulic lines. Anti Lock Braking System ABS: ABS control module, wheel speed sensors, hydraulic unit, and diagnostic procedures. Body Exterior: Body panel repair, door mechanisms, hood, tailgate, bumpers, and trim pieces. Body Interior: Seat removal and repair, dashboard components, headliner, and trim panels. Climate Control System: HVAC unit, blower motor, evaporator, condenser, refrigerant handling, and controls. Electrical System Lighting: Headlights, taillights, interior lighting, fog lights, and related wiring. Electrical System Power Distribution: Fuse box locations, relay identification, battery, alternator, and starting system. Electrical System Instruments Gauges: Instrument cluster diagnosis and repair, warning lights, and sensor inputs. Infotainment Audio System: Radio, speakers, amplifier (if equipped), and antenna system. Safety Airbags: Airbag system components, control module, sensors, and replacement procedures. Safety Seatbelts: Seatbelt mechanisms, pre-tensioners, and inspection. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspections. Scheduled Maintenance: Detailed service intervals and recommended maintenance tasks based on mileage or time. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex issues. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation. Component Replacement: Guidance on replacing parts such as alternators, starters, water pumps, brake pads, etc. Engine Rebuild: Comprehensive instructions for engine disassembly, inspection, machining, and reassembly. Transmission Rebuild: Detailed procedures for overhauling both manual and automatic transmissions. Electrical Diagnostics: Using wiring diagrams and test equipment to diagnose electrical faults. Wheel Alignment: Specifications and procedures for front and rear wheel alignment. HVAC Service: Refrigerant charging, leak detection, and component replacement for the climate control system. Technical Depth Diagnostic Capabilities: Advanced diagnostics including DTC interpretation, sensor data analysis, and actuator testing. Specification Data: Torque specifications, clearances, fluid capacities, resistance values, and electrical parameters. Diagrams Illustrations: Hundreds of detailed photos and exploded diagrams for visual guidance. Service Tips: Professional insights and tips for performing repairs efficiently and correctly. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding Type: Digital (no physical binding) Paper Type Paper Type: Not applicable (digital format) Software Requirements Compatibility: Compatible with all Windows and MAC computers. Licensing Usage License: Lifetime use on unlimited computers, no expiry dates, no renewal fees. ⚙️ Engine Specifications Primary Engine Engine Displacement Common: Likely a 2.7-liter diesel engine (e.g., Mercedes-Benz derived) as was common for SsangYong at this time. Petrol engines may also be present depending on market, potentially...
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SsangYong Rexton Y250 2006-2008 Service Repair Workshop Manual Pdf
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Rexton
Model Code:
Y250
Model Years Covered:
2006, 2007, 2008
👋 Introduction
Market Position
Vehicle Class:
Body-on-frame SUV, often marketed as a capable and rugged utility vehicle.
Competitive Analysis
Direct Competitors 2006-2008:
SsangYong Rexton competed against SUVs like the Kia Sorento, Hyundai Santa Fe (earlier generations), Mitsubishi Pajero/Montero Sport, and Ford Everest (depending on market).
Key Features Vehicle
Body Style:
Full-size SUV with a strong emphasis on utility and off-road capability.
Powertrain Layout:
Typically rear-wheel drive (RWD) with optional four-wheel drive (4WD) selectable systems, common for its class.
Key Features Manual
Manual Value Proposition:
Comprehensive factory-level information for DIY repairs and professional workshop use, offering significant cost savings over dealership service.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Global (typical for factory manuals, specific regional variations may exist but not detailed in product info)
Market Coverage:
All markets where the Rexton Y250 was sold
Page Count
Estimated Page Count:
Hundreds (as stated in description)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
Likely English, typical for factory service manuals targeting international markets. Regional language versions are not specified.
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed information on engine disassembly, assembly, diagnostics, and repair for all variants offered in the Y250 generation.
Engine Control System:
Wiring diagrams, sensor locations, diagnostic trouble codes (DTCs), and troubleshooting for the Engine Control Unit (ECU).
Fuel System:
Fuel injection system diagnosis, pump, injectors, fuel filter replacement, and pressure testing.
Cooling System:
Radiator, thermostat, water pump, fan clutch, hoses, and coolant specifications.
Lubrication System:
Oil pump, oil filter, oil pan, oil specifications, and oil change procedures.
Exhaust System:
Catalytic converter, muffler, exhaust pipes, and oxygen sensors.
Transmission Manual:
Diagnosis, repair, and overhaul procedures for manual transmissions, including clutch service.
Transmission Automatic:
Diagnosis, repair, and overhaul procedures for automatic transmissions, including fluid checks and changes, torque converter service.
Drivetrain Transfer Case:
Service and repair of the transfer case, including 4WD system operation and maintenance.
Drivetrain Axles:
Front and rear axle service, differential repair, and driveshaft maintenance.
Suspension Front:
Struts, control arms, ball joints, tie rod ends, wheel bearings, and alignment specifications.
Suspension Rear:
Shock absorbers, springs, control arms, bushings, and alignment specifications.
Steering System:
Power steering pump, rack and pinion, steering column, and associated components.
Brake System Front:
Disc brake components, calipers, pads, rotors, and hydraulic lines.
Brake System Rear:
Disc or drum brake components, calipers/wheel cylinders, pads/shoes, rotors/drums, and hydraulic lines.
Anti Lock Braking System ABS:
ABS control module, wheel speed sensors, hydraulic unit, and diagnostic procedures.
Body Exterior:
Body panel repair, door mechanisms, hood, tailgate, bumpers, and trim pieces.
Body Interior:
Seat removal and repair, dashboard components, headliner, and trim panels.
Climate Control System:
HVAC unit, blower motor, evaporator, condenser, refrigerant handling, and controls.
Electrical System Lighting:
Headlights, taillights, interior lighting, fog lights, and related wiring.
Electrical System Power Distribution:
Fuse box locations, relay identification, battery, alternator, and starting system.
Electrical System Instruments Gauges:
Instrument cluster diagnosis and repair, warning lights, and sensor inputs.
Infotainment Audio System:
Radio, speakers, amplifier (if equipped), and antenna system.
Safety Airbags:
Airbag system components, control module, sensors, and replacement procedures.
Safety Seatbelts:
Seatbelt mechanisms, pre-tensioners, and inspection.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspections.
Scheduled Maintenance:
Detailed service intervals and recommended maintenance tasks based on mileage or time.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Component Replacement:
Guidance on replacing parts such as alternators, starters, water pumps, brake pads, etc.
Engine Rebuild:
Comprehensive instructions for engine disassembly, inspection, machining, and reassembly.
Transmission Rebuild:
Detailed procedures for overhauling both manual and automatic transmissions.
Electrical Diagnostics:
Using wiring diagrams and test equipment to diagnose electrical faults.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
HVAC Service:
Refrigerant charging, leak detection, and component replacement for the climate control system.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics including DTC interpretation, sensor data analysis, and actuator testing.
Specification Data:
Torque specifications, clearances, fluid capacities, resistance values, and electrical parameters.
Diagrams Illustrations:
Hundreds of detailed photos and exploded diagrams for visual guidance.
Service Tips:
Professional insights and tips for performing repairs efficiently and correctly.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding Type:
Digital (no physical binding)
Paper Type
Paper Type:
Not applicable (digital format)
Software Requirements
Compatibility:
Compatible with all Windows and MAC computers.
Licensing
Usage License:
Lifetime use on unlimited computers, no expiry dates, no renewal fees.
⚙️ Engine Specifications
Primary Engine
Engine Displacement Common:
Likely a 2.7-liter diesel engine (e.g., Mercedes-Benz derived) as was common for SsangYong at this time. Petrol engines may also be present depending on market, potentially 3.2L.
Engine Type Common:
Common Rail Direct Injection (CRDi) Turbo Diesel, or Inline-4/Inline-5 Petrol.
Performance
Horsepower Range Diesel Est:
Approximately 160-190 hp (depending on specific engine variant).
Torque Range Diesel Est:
Approximately 340-400 Nm (depending on specific engine variant).
Fuel System
Fuel Injection Type:
Electronic fuel injection (common rail for diesel, multi-point or direct for petrol).
🔧 Transmission
Standard
Standard Transmission Type:
Likely a 5-speed manual transmission.
Optional
Optional Transmission Type:
Likely a 5-speed automatic transmission.
Features
Drivetrain Options:
Available in RWD and part-time 4WD configurations.
📐 Dimensions
Exterior
Body Style:
5-door SUV.
Weights
Curb Weight Est:
Approximately 2000-2200 kg (depending on configuration).
💡 Technology Features
Infotainment
Infotainment System Features:
Basic infotainment typically includes an AM/FM radio with CD player, potentially MP3 capability, and a limited number of speakers. Navigation was an optional extra, if available at all.
Driver Assistance
Driver Assistance Features Available:
Limited driver assistance systems. ABS was standard. Traction control and Electronic Stability Program (ESP) may have been optional on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval Diesel:
Typically every 5,000 to 10,000 km or 6-12 months for diesel engines, depending on driving conditions. Refer to manual for specific recommendation.
Air Filter Replacement:
Recommended every 20,000-30,000 km or annually.
Fuel Filter Replacement Diesel:
Crucial for diesel engines, typically every 40,000-60,000 km.
Fluid Specifications
Engine Oil Specification Diesel:
Likely API CI-4 or newer, ACEA E5/E7 specification, SAE 5W-30 or 5W-40 viscosity. Consult manual for precise spec.
Coolant Specification:
Ethylene glycol based, typically a long-life coolant with specific OAT (Organic Acid Technology) or HOAT formulation. Refer to manual for exact type and color.
Automatic Transmission Fluid Type:
Mercon V or equivalent, or a specific Dexron type. Manual will specify.
Known Issues
Common Diesel Issues:
Potential issues can include glow plug failures, turbocharger problems, injector wear, and EGR valve clogging, especially with high mileage or poor fuel quality. EGR cooler leaks are also a possibility.
Common Suspension Issues:
Wear on bushings, ball joints, and tie rod ends can lead to steering looseness and premature tire wear.
Common Electrical Issues:
Wiring harness issues, sensor failures, and module problems can occur, as with many vehicles of this era.
📚 Vehicle History
Brand Heritage
Ssangyong History Overview:
SsangYong Motor Company, a South Korean manufacturer, has a history of producing robust vehicles, often leveraging Mercedes-Benz technology and powertrains, particularly in its earlier years.
Model Evolution
Rexton Y250 Generation:
The Y250 represents the second generation of the Rexton, building on the platform and concept of the original Rexton (G200/G320) introduced in 2001.
Production
Production Period Y250:
The Y250 generation was produced from 2006 to 2012, with this manual specifically covering the initial 2006-2008 period.
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