SsangYong Rexton Service & Repair Manual 2001-2006 (2 000 pa
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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Generation: First Generation (RJ) Production Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Vehicle Segment: Mid-size/Large SUV (Body-on-frame) Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops, enthusiasts. Competitive Analysis Competitors Era: Competed with vehicles like the Hyundai Terracan, Mitsubishi Pajero Sport, and other ladder-frame SUVs of the early 2000s. Key Features Manual Features: Detailed illustrations, step-by-step instructions, diagnostic procedures, electrical system schematics, troubleshooting guides, notes/cautions/warnings, numbered instructions, figure number referencing, enlarged inset diagrams. Value Proposition Benefit: An inexpensive way to keep the vehicle working properly, mirroring dealer-level service information. 📋 Manual Details Coverage Areas Primary Coverage: SsangYong Rexton Body Styles Covered: All body styles Page Count Total Pages: 2000 Manual Type Type: Service & Repair Manual (Workshop Manual) Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Control System, Emission Control Systems, Cooling System, Fuel System, Lubrication System, Charging System, Starting System, Transmission (likely Manual and Automatic), Differential Case Assy, Drive Shaft, Drive Belt Chassis: Brake System (Brake Master Cylinder, Brake Booster, Brake Actuator, Brake Pedal), Steering System (Power Steering, Steering Column, Steering Sensor), Suspension System (Front Suspension, Rear Suspension, Wheel and Tire System) Body And Interior: Body Repair, Door Systems (Front Door, Rear Door), Glass Systems (Windshield Glass, Quarter Window Assy), Seat Systems, Roof Headlining, Instrument Panel, Interior Trim, Exterior Mouldings (Roof Drip Side Finish Moulding), Bumpers (Rear Bumper) Electrical And Electronics: Wiring Diagrams, Wire Harness Repair, Lighting System (Center Stop Lamp Assy, License Plate Lamp Assy, Side Turn Signal Lamp Assy), Combination Meter, Audio System (Radio Receiver Assy), Power Window Control System, Power Mirror Control System, Power Door Lock Control System, Wiper And Washer System, HVAC System (Heater Radiator Assy), Airbag Systems (Curtain Shield Air Bag Assy, Side Air Bag Sensor Assy, Passenger Air Bag Assy), Supplemental Restraint System, Horn, Windshield Wiper Motor Assy Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, lubrication Repair: Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component diagnosis and repair, body panel repair Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) explanation, electrical system diagnostics Technical Data: Specifications, torque values, clearances, component identification Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete vehicle disassembly and reassembly. Includes detailed diagnostic procedures and repair instructions. 📊 Manual Specifications File Format File Type: PDF Compatibility: Windows, Mac, Linux Print Quality Printability: Printable without restriction Search Features Searchability: Searchable Integrity Completeness: 100% complete and intact, no missing/corrupt pages/sections Delivery Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Options: Likely included Mercedes-Benz derived diesel engines (e.g., OM601/OM602 variants) and potentially petrol engines (e.g., some inline-4 or inline-5 from Mercedes-Benz or licensed Daewoo/GM engines). Performance Typical Diesel Hp Range: Approximately 100-130 hp for common diesel variants Typical Diesel Torque Range: Approximately 240-280 Nm for common diesel variants Fuel System Diesel Injection: Likely direct injection or indirect injection, possibly with mechanical or electronic control depending on the specific engine variant. Engine Management ECU Type: Engine Control Unit (ECU) for fuel injection and engine management, detailed in wiring diagrams. Cooling Cooling System Type: Pressurized liquid cooling system with radiator, fan, water pump, and thermostat. Lubrication Oil Type Recommendation: Will specify API classification (e.g., API CF/SG) and viscosity grade (e.g., 10W-30, 15W-40) for diesel engines. Manual will detail oil filter part numbers. 🔧 Transmission Standard Transmission Transmission Type Availability: Likely offered with both manual and automatic transmissions. Optional Transmission Automatic Transmission: Potentially a Mercedes-Benz sourced automatic transmission (e.g., 722.6 family or similar). Features Drivetrain: Often available in 2WD (RWD) and 4WD configurations, with the manual likely detailing transfer case operation. Maintenance Fluid Specifications: Will specify automatic transmission fluid (ATF) type (e.g., Dexron III, Mercon) and manual transmission fluid (MTF) viscosity and specification. Capacities will be provided. 📐 Dimensions Exterior Body Type: Body-on-frame SUV Weights Curb Weight Range: Typically in the range of 1900-2200 kg, depending on engine and drivetrain. Gross Vehicle Weight Rating: Will be specified in the manual for payload calculations. 🛡️ Safety Features Passive Features Airbags: Front airbags for driver and passenger, likely side airbags in some trims. Seat Belts: Front and rear seat belts, with pretensioners and load limiters for front occupants. Active Features ABS: Anti-lock Braking System (ABS) likely standard or optional depending on trim. Traction Control: Traction Control System (TCS) and Electronic Stability Program (ESP) may be available on higher trims. Ratings Crash Test Data: Specific crash test ratings from organizations like Euro NCAP or NHTSA would need to be researched separately, but the manual will cover SRS component function. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player or cassette player, likely with auxiliary inputs. Manual covers head unit removal and basic diagnostics. Driver Assistance Cruise Control: Cruise control was likely available...
Owners seeking to perform DIY maintenance and repairs, independent repair shops, enthusiasts.
Competitive Analysis
Competitors Era:
Competed with vehicles like the Hyundai Terracan, Mitsubishi Pajero Sport, and other ladder-frame SUVs of the early 2000s.
Key Features Manual
Features:
Detailed illustrations, step-by-step instructions, diagnostic procedures, electrical system schematics, troubleshooting guides, notes/cautions/warnings, numbered instructions, figure number referencing, enlarged inset diagrams.
Value Proposition
Benefit:
An inexpensive way to keep the vehicle working properly, mirroring dealer-level service information.
📋 Manual Details
Coverage Areas
Primary Coverage:
SsangYong Rexton
Body Styles Covered:
All body styles
Page Count
Total Pages:
2000
Manual Type
Type:
Service & Repair Manual (Workshop Manual)
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Engine Control System, Emission Control Systems, Cooling System, Fuel System, Lubrication System, Charging System, Starting System, Transmission (likely Manual and Automatic), Differential Case Assy, Drive Shaft, Drive Belt
Chassis:
Brake System (Brake Master Cylinder, Brake Booster, Brake Actuator, Brake Pedal), Steering System (Power Steering, Steering Column, Steering Sensor), Suspension System (Front Suspension, Rear Suspension, Wheel and Tire System)
Body And Interior:
Body Repair, Door Systems (Front Door, Rear Door), Glass Systems (Windshield Glass, Quarter Window Assy), Seat Systems, Roof Headlining, Instrument Panel, Interior Trim, Exterior Mouldings (Roof Drip Side Finish Moulding), Bumpers (Rear Bumper)
Electrical And Electronics:
Wiring Diagrams, Wire Harness Repair, Lighting System (Center Stop Lamp Assy, License Plate Lamp Assy, Side Turn Signal Lamp Assy), Combination Meter, Audio System (Radio Receiver Assy), Power Window Control System, Power Mirror Control System, Power Door Lock Control System, Wiper And Washer System, HVAC System (Heater Radiator Assy), Airbag Systems (Curtain Shield Air Bag Assy, Side Air Bag Sensor Assy, Passenger Air Bag Assy), Supplemental Restraint System, Horn, Windshield Wiper Motor Assy
Comprehensive: Covers everything from basic maintenance to complete vehicle disassembly and reassembly. Includes detailed diagnostic procedures and repair instructions.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows, Mac, Linux
Print Quality
Printability:
Printable without restriction
Search Features
Searchability:
Searchable
Integrity
Completeness:
100% complete and intact, no missing/corrupt pages/sections
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely included Mercedes-Benz derived diesel engines (e.g., OM601/OM602 variants) and potentially petrol engines (e.g., some inline-4 or inline-5 from Mercedes-Benz or licensed Daewoo/GM engines).
Performance
Typical Diesel Hp Range:
Approximately 100-130 hp for common diesel variants
Typical Diesel Torque Range:
Approximately 240-280 Nm for common diesel variants
Fuel System
Diesel Injection:
Likely direct injection or indirect injection, possibly with mechanical or electronic control depending on the specific engine variant.
Engine Management
ECU Type:
Engine Control Unit (ECU) for fuel injection and engine management, detailed in wiring diagrams.
Cooling
Cooling System Type:
Pressurized liquid cooling system with radiator, fan, water pump, and thermostat.
Lubrication
Oil Type Recommendation:
Will specify API classification (e.g., API CF/SG) and viscosity grade (e.g., 10W-30, 15W-40) for diesel engines. Manual will detail oil filter part numbers.
🔧 Transmission
Standard Transmission
Transmission Type Availability:
Likely offered with both manual and automatic transmissions.
Optional Transmission
Automatic Transmission:
Potentially a Mercedes-Benz sourced automatic transmission (e.g., 722.6 family or similar).
Features
Drivetrain:
Often available in 2WD (RWD) and 4WD configurations, with the manual likely detailing transfer case operation.
Maintenance
Fluid Specifications:
Will specify automatic transmission fluid (ATF) type (e.g., Dexron III, Mercon) and manual transmission fluid (MTF) viscosity and specification. Capacities will be provided.
📐 Dimensions
Exterior
Body Type:
Body-on-frame SUV
Weights
Curb Weight Range:
Typically in the range of 1900-2200 kg, depending on engine and drivetrain.
Gross Vehicle Weight Rating:
Will be specified in the manual for payload calculations.
🛡️ Safety Features
Passive Features
Airbags:
Front airbags for driver and passenger, likely side airbags in some trims.
Seat Belts:
Front and rear seat belts, with pretensioners and load limiters for front occupants.
Active Features
ABS:
Anti-lock Braking System (ABS) likely standard or optional depending on trim.
Traction Control:
Traction Control System (TCS) and Electronic Stability Program (ESP) may be available on higher trims.
Ratings
Crash Test Data:
Specific crash test ratings from organizations like Euro NCAP or NHTSA would need to be researched separately, but the manual will cover SRS component function.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player, likely with auxiliary inputs. Manual covers head unit removal and basic diagnostics.
Driver Assistance
Cruise Control:
Cruise control was likely available on higher trim levels.
Connectivity
Wiring For Accessories:
Wiring diagrams will assist in adding aftermarket accessories and understanding existing electrical connections.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and engine type (diesel vs. petrol). Specifics in manual.
Timing Belt Interval:
If fitted with a timing belt (some diesel engines), replacement is critical, typically around 80,000-100,000 km. Manual will specify if it uses a belt or chain and interval.
Transmission Fluid Interval:
Automatic transmission fluid changes typically every 40,000-80,000 km. Manual transmission fluid checks and changes as per manual.
Fluid Specifications
Coolant Type:
Likely a silicate-free ethylene glycol based antifreeze/coolant, specified by SsangYong or equivalent (e.g., G11/G12).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, as specified by the manufacturer.
Known Issues
Common Problems:
Potential issues can include glow plug failures (diesel), EGR valve issues (diesel), turbocharger problems (diesel), occasional electrical gremlins, and wear on suspension components due to its off-road capability. Manual is key for diagnosis.
Component Replacement
Filter Part Numbers:
Manual will provide specific part numbers for oil filters, fuel filters, air filters, and cabin filters for various engine options.
📚 Vehicle History
Brand Heritage
Brand Origin:
SsangYong Motor Company, a South Korean manufacturer with historical ties to technology sharing with Mercedes-Benz.
Model Evolution
Development Basis:
The Rexton was developed as a successor to the SsangYong Korando Family and Musso, utilizing Mercedes-Benz technology, particularly in its powertrains.
Production
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Industry Accolades:
Specific awards for the Rexton are not widely documented in major automotive publications for this era, but its use of Mercedes-Benz powertrain technology was a key selling point.
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