Ssangyong Y200 Rexton 2001-2006 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ssangyong Model: Rexton Product Name: Ssangyong Y200 Rexton 2001-2006 Workshop Service Repair Manual PDF Generation Generation Code: Y200 Codes Chassis Code: Y200 👋 Introduction Market Position Vehicle Segment: Full-size SUV Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive technicians Competitive Analysis Competitors: During its production era, the Rexton competed with SUVs like the Mitsubishi Pajero/Montero, Hyundai Terracan, and similarly sized vehicles from other manufacturers. Key Features Manual Benefits: Empowers owners to perform professional-level maintenance and repairs, saving on labor costs and improving vehicle longevity. Provides accurate technical data comparable to dealer service departments. Manual Emphasis: Focuses on specific aspects of the Ssangyong Rexton Y200, highlighting unique procedures and proprietary components. 📋 Manual Details Coverage Areas Covered Years: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Extensive (Specific page count not provided, typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Full repair, overhaul, tune-ups, lubrication system, fuel system, cooling system Transmission: Removal, installation, overhaul, repair procedures (automatic and manual, if applicable) Drivetrain: Driveshafts, axles, differentials, four-wheel drive system (if equipped) Suspension: Front and rear suspension components, adjustments, overhaul Steering: Steering column, power steering system, components Brakes: Brake system components, hydraulic system, ABS (if equipped), maintenance, repair Electrical System: Wiring diagrams, charging system, starting system, lighting, instruments, electronic control units (ECUs) Fuel System: Fuel tank, fuel pump, injectors, fuel lines, fuel pressure Ignition System: Spark plugs, ignition coils, timing Exhaust System: Exhaust manifold, pipes, muffler, catalytic converter Body And Chassis: Body panels, doors, windows, interior trim, structural components, rustproofing HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotation, tune-ups Troubleshooting: Diagnostic procedures for common and complex issues, symptom-based troubleshooting Repair And Overhaul: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation Technical Specifications: Torque specifications, fluid capacities, clearances, tolerances Special Tools: Identification and usage instructions for Ssangyong-specific or recommended special tools Component Specific Instructions: Detailed procedures for proprietary components, referencing manufacturer guidelines where applicable Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick access to specific information Print Quality Printability: Printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Likely various diesel engines (e.g., Mercedes-Benz derived inline-5) and potentially gasoline options depending on market. Specific engine codes not provided in product info. Engine Displacement: Commonly 2.7L diesel (e.g., OM662LA) and potentially 3.2L gasoline engines. Performance Horsepower: Varies by engine, typically ranging from 120-170 HP for diesel variants. Torque: Varies by engine, typically in the range of 250-350 Nm for diesel variants. Fuel System Fuel Delivery: Likely electronic diesel injection (common rail) or gasoline fuel injection depending on engine variant. Cooling System Coolant Type: Typically a glycol-based coolant (e.g., G11 or G12 specification), check manual for exact type. 🔧 Transmission Standard Transmission Type: Likely a 5-speed manual transmission and a 5-speed automatic transmission (e.g., Mercedes-Benz 722.6 '5G-Tronic' in some models). Optional Optional Transmission: Automatic transmission if manual is standard, or vice-versa depending on market and trim. Features Drivetrain Options: Available in RWD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations. Fluid Specifications Automatic Transmission Fluid: Likely Mercedes-Benz specification fluid (e.g., ATF 3353 or equivalent) for 722.6 transmission. Consult manual for exact specification. Manual Transmission Fluid: GL-4 or GL-5 gear oil, with specific viscosity...
Ssangyong Y200 Rexton 2001-2006 Workshop Service Repair Manual PDF
Generation
Generation Code:
Y200
Codes
Chassis Code:
Y200
👋 Introduction
Market Position
Vehicle Segment:
Full-size SUV
Target Audience:
Owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive technicians
Competitive Analysis
Competitors:
During its production era, the Rexton competed with SUVs like the Mitsubishi Pajero/Montero, Hyundai Terracan, and similarly sized vehicles from other manufacturers.
Key Features
Manual Benefits:
Empowers owners to perform professional-level maintenance and repairs, saving on labor costs and improving vehicle longevity. Provides accurate technical data comparable to dealer service departments.
Manual Emphasis:
Focuses on specific aspects of the Ssangyong Rexton Y200, highlighting unique procedures and proprietary components.
📋 Manual Details
Coverage Areas
Covered Years:
2001, 2002, 2003, 2004, 2005, 2006
Page Count
Estimated Page Count:
Extensive (Specific page count not provided, typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Full repair, overhaul, tune-ups, lubrication system, fuel system, cooling system
Transmission:
Removal, installation, overhaul, repair procedures (automatic and manual, if applicable)
Drivetrain:
Driveshafts, axles, differentials, four-wheel drive system (if equipped)
Suspension:
Front and rear suspension components, adjustments, overhaul
Steering:
Steering column, power steering system, components
Brakes:
Brake system components, hydraulic system, ABS (if equipped), maintenance, repair
Electrical System:
Wiring diagrams, charging system, starting system, lighting, instruments, electronic control units (ECUs)
Identification and usage instructions for Ssangyong-specific or recommended special tools
Component Specific Instructions:
Detailed procedures for proprietary components, referencing manufacturer guidelines where applicable
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick access to specific information
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Likely various diesel engines (e.g., Mercedes-Benz derived inline-5) and potentially gasoline options depending on market. Specific engine codes not provided in product info.
Engine Displacement:
Commonly 2.7L diesel (e.g., OM662LA) and potentially 3.2L gasoline engines.
Performance
Horsepower:
Varies by engine, typically ranging from 120-170 HP for diesel variants.
Torque:
Varies by engine, typically in the range of 250-350 Nm for diesel variants.
Fuel System
Fuel Delivery:
Likely electronic diesel injection (common rail) or gasoline fuel injection depending on engine variant.
Cooling System
Coolant Type:
Typically a glycol-based coolant (e.g., G11 or G12 specification), check manual for exact type.
🔧 Transmission
Standard
Transmission Type:
Likely a 5-speed manual transmission and a 5-speed automatic transmission (e.g., Mercedes-Benz 722.6 '5G-Tronic' in some models).
Optional
Optional Transmission:
Automatic transmission if manual is standard, or vice-versa depending on market and trim.
Features
Drivetrain Options:
Available in RWD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations.
Fluid Specifications
Automatic Transmission Fluid:
Likely Mercedes-Benz specification fluid (e.g., ATF 3353 or equivalent) for 722.6 transmission. Consult manual for exact specification.
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, with specific viscosity (e.g., 75W-90). Consult manual for exact specification.
📐 Dimensions
Exterior
Length:
Approximately 4730 mm (186.2 in)
Width:
Approximately 1870 mm (73.6 in)
Height:
Approximately 1745 mm (68.7 in)
Weights
Curb Weight:
Varies by configuration, typically around 1900-2100 kg (4189-4630 lbs)
Gross Vehicle Weight Rating:
Typically around 2700-2900 kg (5952-6393 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Vehicle safety ratings for this era and make may vary by region. Specific official ratings for the Y200 Rexton are not readily available in generalized data but would be detailed in the manual if tested by regional bodies.
Active Features
Traction Control:
Available on higher trims or as an option.
Electronic Stability Program:
Likely available on later models or as an option.
Anti Lock Braking System:
Standard on most models, detailed in the manual.
Passive Features
Airbags:
Front airbags for driver and passenger; side airbags may be optional or standard on higher trims.
Seatbelts:
Three-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, possibly cassette player. Speakers distributed throughout the cabin. Higher trims might offer premium sound systems.
Navigation:
Optional factory navigation system may have been available on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most models, with operation detailed in the manual.
Connectivity
Power Outlets:
12V power outlets in the dashboard and center console for accessory charging.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles (12,000 - 15,000 km) or 12 months, depending on driving conditions. Consult manual for exact interval based on engine oil type.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.
Fuel Filter Replacement:
Typically every 30,000 - 45,000 miles (48,000 - 72,000 km) for diesel, varies for gasoline. Consult manual.
Fluid Specifications
Engine Oil Specification:
Depends on engine. For diesel engines, typically API CI-4 or CH-4 synthetic or semi-synthetic 5W-30 or 10W-40. For gasoline, API SN/SM/SL with appropriate viscosity. Consult manual for precise MB-approval or ACEA specs.
Engine Oil Capacity:
Approx. 7.5 - 8.5 liters (7.9 - 9.0 US quarts) for diesel engines. Varies for gasoline. Consult manual.
Potential issues can include EGR valve problems (diesel), glow plug issues (diesel), suspension component wear, and minor electrical gremlins. Specific detailed information will be in the manual.
General Tips
Safety Precautions:
Emphasis on using proper safety equipment (gloves, eye protection, jack stands) and observing warnings/cautions within the manual. Use of a torque wrench is critical for component reassembly.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Model Evolution
First Generation:
The Ssangyong Rexton (Y200) was introduced in 2001, marking Ssangyong's entry into the large SUV segment, often leveraging Mercedes-Benz technology for powertrains and chassis components.
Production
Production Period:
2001-2006 (for the Y200 generation covered by this manual)
Manufacturing Plant:
Primarily manufactured in South Korea.
🏆 Awards & Recognition
Recognitions
Awards:
Specific major awards for the Ssangyong Rexton Y200 are not widely publicized, but it was positioned as a rugged and capable SUV. The manual's value lies in its technical accuracy for owners and technicians.