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SSANGYONG REXTON 2010-2012 full Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Generation: RJ Years Covered: 2010-2012 Market Segment: Full-size SUV 👋 Introduction Market Position Segment: Body-on-frame, large SUV designed for utility and comfort, often positioned as a value-oriented alternative to premium large SUVs. Competitive Analysis Competitors: Competed against vehicles like the Hyundai Santa Fe (earlier generations), Kia Sorento (earlier generations), Mitsubishi Pajero Sport, and similar large SUVs from various markets. Key Features Strengths: Robust chassis, powerful diesel engines, spacious interior, capable off-road (especially with AWD/4WD), often competitively priced. 📋 Manual Details Coverage Areas Coverage: Comprehensive workshop service and repair Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Engine assembly, control, fuel, intake, exhaust, lubrication, cooling, starting, charging, turbocharging, E-EGR, CDPF Drivetrain: Automatic transmission, manual transmission, all-wheel drive, axle, propeller shaft, transfer case Chassis: Brake system, ABS, suspension, steering, wheels and tires Electrical And Electronics: Charging system, cruise control, instrument cluster, immobilizer, electric accessories, wiring diagrams Body And Interior: Body and accessories, interior, exterior, air conditioning Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Diagnostics And Troubleshooting: Fault diagnosis, DTC interpretation, troubleshooting guides for all systems Repair And Rebuild: Component disassembly, reassembly, repair procedures for engine, transmission, suspension, brakes, etc. Component Replacement: Replacement of major and minor components across all systems Electrical Repair: Wiring harness repair, component testing, troubleshooting electrical faults Wheel Alignment: Specifications for wheel alignment and procedures for adjustment. Brake Pad Replacement: Detailed steps for front and rear brake pad and disc replacement, including caliper service. Timing Chain Inspection Replacement: Procedures for inspecting and replacing timing chains (if applicable to specific engines) and associated components like tensioners and guides. Radiator And Cooling Fan Replacement: Steps for removing and replacing the radiator, coolant hoses, and cooling fan assembly. Technical Depth Depth: In-depth technical information suitable for professional technicians and advanced DIYers Torque Specifications: Comprehensive list of torque specifications for critical fasteners throughout the vehicle. Schematics Diagrams: Detailed electrical wiring diagrams, vacuum diagrams, and component layout illustrations. 📊 Manual Specifications File Format File Type: PDF Print Quality Searchability: Searchable text (OCR processed) Image Quality: High-resolution diagrams, illustrations, and photographs Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1: 2.0L D20DTR Diesel Engine Engine 2: 2.7L D27DT Diesel Engine Engine 3: 2.7L D27DTP Turbocharged Diesel Engine Engine 4: 3.2L G32D Petrol Engine Performance D20Dtr Power: Approx. 145-165 PS (Varies by specific market tune) D27Dt Power: Approx. 165-170 PS D27Dtp Power: Approx. 186 PS G32D Power: Approx. 220 PS Fuel System Diesel Injection: Common Rail Direct Injection (CRDi) for diesel engines Petrol Injection: Multi-point Fuel Injection (MPI) for petrol engine Emission Controls Dpf: Diesel Particulate Filter (CDPF) system covered for diesel variants Egr: Exhaust Gas Recirculation (E-EGR) system covered 🔧 Transmission Standard Manual Option: Yes, manual transmission available (likely 5 or 6-speed) Optional Automatic Option: Yes, automatic transmission available (likely 5-speed) Features AWD: All-Wheel Drive system covered, likely selectable or full-time depending on trim. Transfer Case: Detailed information on the transfer case operation and maintenance 📐 Dimensions Exterior Length: Approx. 4650-4750 mm (Varies by specific model and year) Width: Approx. 1845-1870 mm Height: Approx. 1740-1770 mm Weights Curb Weight: Approx. 1900-2100 kg (Varies by engine and drivetrain) Towing Capacity: Typically around 2000-2500 kg (check specific market specifications) 🛡️ Safety Features Ratings Crash Test Results: Refer to specific regional safety agency ratings (e.g., Euro NCAP, NHTSA) as availability and results may vary. Early models might have less comprehensive modern safety systems. Active Features ABS: Anti-lock Braking System (ABS) covered extensively Esp: Electronic Stability Program (ESP) or similar may be available on certain trims/years, covered in manual. Passive Features Airbags: Front airbags, side airbags, and curtain airbags covered as applicable. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with likely auxiliary input. Higher trims might offer premium audio systems and navigation. Driver Assistance Cruise Control: Cruise control system coverage included, often standard on higher trims. Connectivity Parking Sensors: Optional rear parking sensors may have been fitted, with diagnostic and repair information provided. Other Features Immobilizer: Integrated immobilizer system and its troubleshooting covered. 🔧 Maintenance Service Intervals Oil Change Interval Diesel: Typically 7,500 to 10,000 miles or 12 months (refer to manual for exact recommendation based on driving conditions and engine variant). Oil Change Interval Petrol: Typically 5,000 to 7,500 miles or 12 months (refer to manual for exact recommendation). Timing Belt Chain: Diesel engines typically use timing chains. Petrol engine timing mechanism should be checked as per manual schedule (potentially a chain or belt). Fluid Specifications Engine Oil Diesel: API CI-4 or ACEA E7/E5 specifications, SAE 5W-30 or 10W-40 (refer to manual for exact grade and capacity). Engine Oil Petrol: API SN/SM or ACEA A3/B4 specifications, SAE...
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SSANGYONG REXTON 2010-2012 full Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Rexton
Generation:
RJ
Years Covered:
2010-2012
Market Segment:
Full-size SUV
👋 Introduction
Market Position
Segment:
Body-on-frame, large SUV designed for utility and comfort, often positioned as a value-oriented alternative to premium large SUVs.
Competitive Analysis
Competitors:
Competed against vehicles like the Hyundai Santa Fe (earlier generations), Kia Sorento (earlier generations), Mitsubishi Pajero Sport, and similar large SUVs from various markets.
Key Features
Strengths:
Robust chassis, powerful diesel engines, spacious interior, capable off-road (especially with AWD/4WD), often competitively priced.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive workshop service and repair
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Engine assembly, control, fuel, intake, exhaust, lubrication, cooling, starting, charging, turbocharging, E-EGR, CDPF
Drivetrain:
Automatic transmission, manual transmission, all-wheel drive, axle, propeller shaft, transfer case
Chassis:
Brake system, ABS, suspension, steering, wheels and tires
Electrical And Electronics:
Charging system, cruise control, instrument cluster, immobilizer, electric accessories, wiring diagrams
Body And Interior:
Body and accessories, interior, exterior, air conditioning
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostics And Troubleshooting:
Fault diagnosis, DTC interpretation, troubleshooting guides for all systems
Repair And Rebuild:
Component disassembly, reassembly, repair procedures for engine, transmission, suspension, brakes, etc.
Component Replacement:
Replacement of major and minor components across all systems
Electrical Repair:
Wiring harness repair, component testing, troubleshooting electrical faults
Wheel Alignment:
Specifications for wheel alignment and procedures for adjustment.
Brake Pad Replacement:
Detailed steps for front and rear brake pad and disc replacement, including caliper service.
Timing Chain Inspection Replacement:
Procedures for inspecting and replacing timing chains (if applicable to specific engines) and associated components like tensioners and guides.
Radiator And Cooling Fan Replacement:
Steps for removing and replacing the radiator, coolant hoses, and cooling fan assembly.
Technical Depth
Depth:
In-depth technical information suitable for professional technicians and advanced DIYers
Torque Specifications:
Comprehensive list of torque specifications for critical fasteners throughout the vehicle.
Schematics Diagrams:
Detailed electrical wiring diagrams, vacuum diagrams, and component layout illustrations.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Searchability:
Searchable text (OCR processed)
Image Quality:
High-resolution diagrams, illustrations, and photographs
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.0L D20DTR Diesel Engine
Engine 2:
2.7L D27DT Diesel Engine
Engine 3:
2.7L D27DTP Turbocharged Diesel Engine
Engine 4:
3.2L G32D Petrol Engine
Performance
D20Dtr Power:
Approx. 145-165 PS (Varies by specific market tune)
D27Dt Power:
Approx. 165-170 PS
D27Dtp Power:
Approx. 186 PS
G32D Power:
Approx. 220 PS
Fuel System
Diesel Injection:
Common Rail Direct Injection (CRDi) for diesel engines
Petrol Injection:
Multi-point Fuel Injection (MPI) for petrol engine
Emission Controls
Dpf:
Diesel Particulate Filter (CDPF) system covered for diesel variants
Egr:
Exhaust Gas Recirculation (E-EGR) system covered
🔧 Transmission
Standard
Manual Option:
Yes, manual transmission available (likely 5 or 6-speed)
Optional
Automatic Option:
Yes, automatic transmission available (likely 5-speed)
Features
AWD:
All-Wheel Drive system covered, likely selectable or full-time depending on trim.
Transfer Case:
Detailed information on the transfer case operation and maintenance
📐 Dimensions
Exterior
Length:
Approx. 4650-4750 mm (Varies by specific model and year)
Width:
Approx. 1845-1870 mm
Height:
Approx. 1740-1770 mm
Weights
Curb Weight:
Approx. 1900-2100 kg (Varies by engine and drivetrain)
Towing Capacity:
Typically around 2000-2500 kg (check specific market specifications)
🛡️ Safety Features
Ratings
Crash Test Results:
Refer to specific regional safety agency ratings (e.g., Euro NCAP, NHTSA) as availability and results may vary. Early models might have less comprehensive modern safety systems.
Active Features
ABS:
Anti-lock Braking System (ABS) covered extensively
Esp:
Electronic Stability Program (ESP) or similar may be available on certain trims/years, covered in manual.
Passive Features
Airbags:
Front airbags, side airbags, and curtain airbags covered as applicable.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with likely auxiliary input. Higher trims might offer premium audio systems and navigation.
Driver Assistance
Cruise Control:
Cruise control system coverage included, often standard on higher trims.
Connectivity
Parking Sensors:
Optional rear parking sensors may have been fitted, with diagnostic and repair information provided.
Other Features
Immobilizer:
Integrated immobilizer system and its troubleshooting covered.
🔧 Maintenance
Service Intervals
Oil Change Interval Diesel:
Typically 7,500 to 10,000 miles or 12 months (refer to manual for exact recommendation based on driving conditions and engine variant).
Oil Change Interval Petrol:
Typically 5,000 to 7,500 miles or 12 months (refer to manual for exact recommendation).
Timing Belt Chain:
Diesel engines typically use timing chains. Petrol engine timing mechanism should be checked as per manual schedule (potentially a chain or belt).
Fluid Specifications
Engine Oil Diesel:
API CI-4 or ACEA E7/E5 specifications, SAE 5W-30 or 10W-40 (refer to manual for exact grade and capacity).
Engine Oil Petrol:
API SN/SM or ACEA A3/B4 specifications, SAE 5W-30 or 0W-30 (refer to manual for exact grade and capacity).
Coolant:
Ethylene glycol-based coolant with appropriate corrosion inhibitors (e.g., Dex-Cool compatible or manufacturer-specific OAT/HOAT type). Capacity: ~8-10 liters.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Capacity: ~1 liter.
Automatic Transmission Fluid:
Manufacturer-specified ATF (e.g., Dexron III/VI equivalent or specific SsangYong fluid). Capacity: ~8-10 liters for complete fluid change.
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, SAE 75W-90 (refer to manual for exact specification and capacity).
Transfer Case Fluid:
Refer to manual for specific gear oil type and capacity.
Differentials Fluid:
API GL-5 gear oil, SAE 75W-90 or 80W-90 (front and rear, check manual for LSD if equipped).
Known Issues
Diesel Particulate Filter:
Potential for DPF clogging if frequently used for short trips without adequate regeneration cycles.
Egr Valve:
EGR valve can become clogged with carbon deposits, leading to performance issues and fault codes.
Suspension Components:
Wear on ball joints, control arm bushings, and shock absorbers, particularly in higher mileage vehicles or those driven on rough roads.
Electronics:
Occasional reports of minor electrical gremlins or sensor failures, common in vehicles of this age. The manual's wiring diagrams are crucial for diagnosis.
Turbocharger:
While generally robust, turbocharger issues can arise from poor maintenance, oil starvation, or excessive heat.
📚 Vehicle History
Brand Heritage
Ssangyong Origins:
SsangYong Motor Company, a South Korean manufacturer, has a history dating back to 1954, with a specialization in SUVs and commercial vehicles. It has had various ownerships, including Daewoo, SAAB, and Mahindra & Mahindra.
Model Evolution
Rexton Lineage:
The Rexton nameplate has been in production since 2001. The 2010-2012 models represent the second generation (RJ), which received a significant facelift and updates to engines and features compared to the original Rexton.
Production
Manufacturing Location:
Primarily manufactured in South Korea at SsangYong's Pyeongtaek plant.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While not frequently winning major international awards compared to mainstream competitors, the Rexton is often recognized in specific markets for its value proposition and towing capability.
Ratings
Reliability:
Reliability can vary. Proper maintenance as outlined in this manual is key to ensuring longevity. Refer to owner forums and consumer reports for specific long-term reliability trends.
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