2001-2003 Ssangyong Rexton Service Repair Workshop Manual (2001 2002 2003)
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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Year Range: 2001-2003 Codes Platform Code: G1 👋 Introduction Market Position Segment: Mid-size SUV / Off-road utility vehicle Competitive Analysis Competitors Circa 2001: Hyundai Terracan, Mitsubishi Pajero (Montero), Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery Key Features Target Audience: Individuals seeking a rugged, capable SUV for both on-road comfort and off-road adventures, and those who prefer DIY maintenance. Value Proposition: Cost savings through DIY repairs, in-depth knowledge of vehicle systems, confidence in performing maintenance and repairs. 📋 Manual Details Coverage Areas Overall Scope: Comprehensive service and repair Page Count Estimated Pages: Extensive (exact count not specified, but description implies a full workshop manual) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Engine controls, ECU related components, engine sensors, fuel system (supply, general specifications) Engine Mechanical: Lubrication system, cooling system (coolant flow chart), intake system (air flow chart), exhaust system Electrical: Electrical components, pre-heating system Chassis And Body: Structure, lifting points, tightening torque of standard bolts Braking System: Brake system operation, ABS system components, brake pad/disc replacement, fluid flush. Steering System: Power steering system, steering gear, tie rod ends, steering column. Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, wheel alignment specifications. Procedures Included Maintenance: General maintenance, service intervals (implied by coverage) Diagnostics: Troubleshooting of engine controls, ECU, and sensors Repair: Repair procedures for various systems including engine, fuel, lubrication, cooling, intake, and exhaust Technical Depth Depth: Detailed workshop level, including diagrams and instructions for self-service 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Software Requirement: Adobe PDF Reader Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Typical: M111 (Mercedes-Benz derived inline-4 petrol), OM602/OM601/OM611 (Mercedes-Benz derived diesel engines) Engine Type Petrol: Inline-4 Cylinder, DOHC, 16-valve (example: M111 E23) Engine Displacement Petrol Cc: 2295 (e.g., M111 E23) Engine Type Diesel: Inline-5 Cylinder, SOHC, 2-valve per cylinder (example: OM602.980) Engine Displacement Diesel Cc: 2874 (e.g., OM602.980 2.9 TD) Performance Horsepower Petrol Hp Approx: 150 @ 5500 RPM (M111 E23 approx.) Torque Petrol Nm Approx: 210 @ 4000 RPM (M111 E23 approx.) Horsepower Diesel Hp Approx: 120 @ 4000 RPM (OM602.980 approx.) Torque Diesel Nm Approx: 250 @ 2400 RPM (OM602.980 approx.) Fuel System Fuel Delivery Petrol: Multi-point fuel injection (MPI) Fuel Type: Unleaded Gasoline (RON 95 recommended), Diesel Emissions Control: Catalytic converter, EGR (for diesel) 🔧 Transmission Standard Type: 5-speed Manual Transmission (common on lower trims/diesel) Optional Type: 4-speed Automatic Transmission (common on petrol, higher trims) Features Drive System: Part-time 4WD system with low-range gearing (4L), selectable 2WD/4H/4L Transfer Case: High/Low range transfer case 📐 Dimensions Exterior Length Mm Approx: 4630 Width Mm Approx: 1870 Height Mm Approx: 1780 Wheelbase Mm Approx: 2720 Weights Curb Weight Kg Approx: 1900-2100 (depending on engine/drivetrain) Gross Vehicle Weight Kg Approx: 2500-2700 🛡️ Safety Features Ratings Crash Test Ratings: Not widely published for this model in major international test bodies (e.g., NHTSA, Euro NCAP) Active Features Braking: Front ventilated discs, Rear solid discs; ABS (Anti-lock Braking System) likely standard on higher trims. Traction Control: Optional/not widely available on early models. Passive Features Airbags: Front airbags for driver and passenger (standard on most trims) Seatbelts: 3-point seatbelts with pretensioners (front), 3-point seatbelts (rear) Child Seat Anchors: ISOFIX child seat anchor points (likely in rear seats) 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with CD player or cassette player. Optional external amplifier and speaker systems. Navigation: Rarely equipped, typically aftermarket units were installed. Driver Assistance Cruise Control: Available on higher trim levels. Connectivity Auxiliary Input: Not typically factory equipped, aftermarket solutions required. Comfort Features Climate Control: Manual or automatic climate control systems, depending on trim level. 🔧 Maintenance Service Intervals Oil Change Petrol Km: Every 7,500 - 10,000 km or 6-12 months (check manual for exact recommendation) Oil Change Diesel Km: Every 5,000 - 7,500 km or 6 months (check manual for exact recommendation, often shorter for diesel) Timing Belt Replacement Km: Petrol: ~100,000 km. Diesel: Likely timing chain (durability varies, check manual). Fluid Specifications Engine Oil Petrol: API SG/SH/SJ, ACEA A2-96/A3-96, Viscosity SAE 10W-40 or 5W-40 recommended. (Refer to manual for precise MB approval specifications) Engine Oil Diesel: API CF/CG-4, ACEA B3/B4, Viscosity SAE 10W-40 or 15W-40 recommended. (Refer to manual for precise MB approval specifications) Coolant: Ethylene Glycol based coolant (e.g., MB 325.0/326.0 equivalent for Mercedes-derived systems), typically a 50/50 mix with distilled water. Transmission Fluid Auto: MB 236.1 or 236.3 equivalent ATF (e.g., Dexron II/III type) Transmission Fluid Manual: GL-4 or GL-5 specification gear oil, viscosity SAE 75W-90 or 80W-90. Brake Fluid: DOT 3 or DOT 4 Known Issues Common Problems Petrol: Spark plug fouling,...
Glow plug failure, injection pump issues (especially on older OM602), turbocharger wear, EGR valve clogging, potential for head gasket failure if overheated.
Chassis Electrical:
Wiring harness issues, sensor failures, battery drain problems can occur with age and mileage.
Body Corrosion:
Rust can be an issue in areas with harsh winters and road salt, particularly around wheel arches, sills, and chassis frame.
📚 Vehicle History
Brand Heritage
Heritage:
SsangYong Motor Company (South Korea), known for its SUVs and off-road vehicles, often leveraging Mercedes-Benz technology in its powertrains and components during this era.
Model Evolution
Generation:
First Generation (G1)
Design Basis:
Developed with significant input and technology sharing from Mercedes-Benz, particularly in the chassis and powertrain.
Production
Production Years:
2001-2005 (First Generation)
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Awards:
No widely publicized major awards for this specific model in international markets.