SsangYong Rexton I Rexton II Rexton W Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton I / Rexton II / Rexton W Generation Production Years: 2001-2016 Codes Platform Codes: RJ (Rexton I), Y250 (Rexton II/W) 👋 Introduction Market Position Vehicle Segment: Mid-size/Large SUV, body-on-frame construction Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops. Competitive Analysis Key Competitors: Mitsubishi Pajero Sport, Hyundai Terracan, Kia Sorento (first generation), Ford Everest. Key Features Manual Benefits: Cost savings on repairs, empowerment of owners to maintain their vehicles, comprehensive coverage of all systems. Vehicle Strengths: Robust chassis, capable off-road performance (especially with 4WD), spacious interior, often competitive pricing. 📋 Manual Details Coverage Areas Geographical Coverage: Global (specifications may vary by region) Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete workshop manual) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel system (mechanical and electronic), intake manifold, exhaust manifold. Engine Electrical: Ignition system, starter system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, emissions control systems. Transmission Drivetrain: Manual transmission, automatic transmission (including transfer case and differentials), clutch system, driveshafts, axles, wheel bearings. Suspension Steering: Front suspension (independent double wishbone, coil springs, shock absorbers), rear suspension (multi-link, coil springs, shock absorbers), steering system (power steering pump, rack and pinion), wheel alignment specifications. Brakes: Front and rear brake system (disc brakes), parking brake, anti-lock braking system (ABS), electronic brake-force distribution (EBD), brake fluid specifications and bleeding procedures. Body Chassis: Body structure, chassis frame, exterior panels, doors, hood, tailgate, interior trim, seats, glass, body sealing, rust prevention. Electrical Electronics: Complete vehicle electrical system, battery, charging system, lighting (headlights, taillights, interior), wipers and washers,...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton I / Rexton II / Rexton W

Generation

Production Years:

2001-2016

Codes

Platform Codes:

RJ (Rexton I), Y250 (Rexton II/W)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size/Large SUV, body-on-frame construction

Target Audience:

Owners seeking to perform DIY maintenance and repairs, independent repair shops.

Competitive Analysis

Key Competitors:

Mitsubishi Pajero Sport, Hyundai Terracan, Kia Sorento (first generation), Ford Everest.

Key Features

Manual Benefits:

Cost savings on repairs, empowerment of owners to maintain their vehicles, comprehensive coverage of all systems.

Vehicle Strengths:

Robust chassis, capable off-road performance (especially with 4WD), spacious interior, often competitive pricing.

📋 Manual Details

Coverage Areas

Geographical Coverage:

Global (specifications may vary by region)

Page Count

Estimated Page Count:

Extensive (typically 1000+ pages for a complete workshop manual)

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel system (mechanical and electronic), intake manifold, exhaust manifold.

Engine Electrical:

Ignition system, starter system, charging system, engine control unit (ECU) diagnostics, sensors, actuators, emissions control systems.

Transmission Drivetrain:

Manual transmission, automatic transmission (including transfer case and differentials), clutch system, driveshafts, axles, wheel bearings.

Suspension Steering:

Front suspension (independent double wishbone, coil springs, shock absorbers), rear suspension (multi-link, coil springs, shock absorbers), steering system (power steering pump, rack and pinion), wheel alignment specifications.

Brakes:

Front and rear brake system (disc brakes), parking brake, anti-lock braking system (ABS), electronic brake-force distribution (EBD), brake fluid specifications and bleeding procedures.

Body Chassis:

Body structure, chassis frame, exterior panels, doors, hood, tailgate, interior trim, seats, glass, body sealing, rust prevention.

Electrical Electronics:

Complete vehicle electrical system, battery, charging system, lighting (headlights, taillights, interior), wipers and washers, horn, power windows, central locking, instrument cluster, wiring diagrams, fuses, relays, body control module (BCM).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant type, charging procedures, component testing.

Safety Restraints:

Airbag system, seat belts, pre-tensioners, SRS module diagnostics.

Procedures Included

Maintenance:

Regular maintenance checks, oil changes, filter replacements, fluid top-ups, tire rotations, brake pad inspection, battery maintenance.

Troubleshooting:

Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation.

Repair:

Step-by-step repair instructions for all major vehicle components, including engine overhaul, transmission repair, suspension component replacement, brake system overhaul, electrical component repair.

Installation:

Installation guides for specific components or accessories (where applicable).

Technical Depth

Depth Of Information:

Comprehensive, covering basic maintenance to complete engine rebuilds and complex electrical diagnostics.

Diagnostic Capabilities:

Detailed diagnostic procedures, including sensor data interpretation and component testing.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Printability:

High-quality, printable pages; zoomable for detailed examination of diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Options:

Diverse range including 2.7L Diesel (OM662LA), 2.9L Diesel (OM662LA variant or similar), 3.2L Diesel (OM612 variants or similar Mercedes-Benz sourced), 2.7L Turbo Diesel (OM662LA-based), 3.6L V6 Petrol (M112 Mercedes-Benz sourced).

Performance

Power Output Range:

Approximately 120 HP to 200 HP depending on engine and specific tuning.

Torque Output Range:

Approximately 230 Nm to 400 Nm depending on engine and specific tuning.

Fuel System

Fuel Delivery Systems:

Common Rail Direct Injection (CRDi) for diesel engines, Electronic Fuel Injection (EFI) for petrol engines.

🔧 Transmission

Standard

Standard Transmission Type:

5-speed Manual Transmission (MT) for many variants.

Optional

Optional Transmission Type:

5-speed or 4-speed Automatic Transmission (AT), often sourced from Mercedes-Benz (e.g., 722.6 variant for some models).

Features

Drivetrain Options:

Part-time 4WD (Rexton I) or full-time 4WD systems with low-range transfer case on many models.

📐 Dimensions

Exterior

Length:

Approx. 4700-4750 mm

Width:

Approx. 1870-1900 mm

Height:

Approx. 1770-1800 mm

Wheelbase:

Approx. 2820-2830 mm

Cargo

Cargo Volume:

Variable, typically around 850-900 liters behind the second row, expandable with seats folded.

Weights

Curb Weight:

Approx. 1900-2100 kg

Gross Vehicle Weight Rating:

Approx. 2700-2900 kg

🛡️ Safety Features

Ratings

Crash Test History:

Varies by market and specific model year; generally considered a robust vehicle for its class but may not meet modern stringent safety standards without specific regional enhancements.

Active Features

Active Safety Features:

ABS, EBD (standard on most models), Traction Control System (TCS) on higher trims and later models, Electronic Stability Program (ESP) on later models.

Passive Features

Passive Safety Features:

Dual front airbags, side airbags (on some models), 3-point seat belts with pre-tensioners, reinforced body structure.

💡 Technology Features

Infotainment

Infotainment Systems:

Varies significantly by trim and year. Base models may have basic AM/FM radio with CD player. Higher trims and later models offer touchscreen infotainment systems with navigation, Bluetooth connectivity, and rearview camera integration.

Driver Assistance

Driver Assistance Features:

Limited on early models. Later models may include parking sensors, rearview cameras, and cruise control.

Connectivity

Connectivity Options:

USB ports, auxiliary input, Bluetooth (on select models and trims).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-10,000 km or 6-12 months, depending on engine oil type and driving conditions. Consult manual for specific engine recommendations.

Air Filter Replacement:

Every 20,000-30,000 km or as per manual, more frequently in dusty conditions.

Fuel Filter Replacement:

Diesel: Every 40,000-60,000 km. Petrol: Less frequent, consult manual.

Fluid Specifications

Engine Oil Specifications:

Varies by engine. Diesel engines often require API CJ-4 or CK-4 compliant synthetic oils (e.g., 5W-30, 10W-30). Petrol engines may require API SN/SP or ILSAC GF-5/GF-6 compliant oils (e.g., 5W-30, 10W-40). Always refer to the specific manual for exact grade and API/ILSAC ratings.

Transmission Fluid Specifications Auto:

Typically Dexron III/VI compatible fluid for older automatics, or specific ATF fluids for Mercedes-Benz sourced transmissions (e.g., ATF 7134). Consult manual for precise type.

Coolant Specifications:

Ethylene glycol-based coolant with anti-corrosion additives. Usually a long-life (OAT) or HOAT type. Refer to manual for specific colour and type (e.g., G12 or similar).

Brake Fluid Specifications:

DOT 3 or DOT 4.

Known Issues

Common Complaints Diesel:

Potential issues with turbocharger reliability (especially on older models), glow plug system faults, EGR valve clogging, exhaust manifold cracking, injector problems.

Common Complaints General:

Rusting on chassis and body panels (particularly older models), occasional electrical gremlins, suspension component wear (bushings, ball joints), power window regulator failures.

Transmission Issues Auto:

Some automatic transmissions, particularly older ones, may exhibit harsh shifting or delayed engagement. Fluid and filter changes are critical for longevity.

📚 Vehicle History

Brand Heritage

Ssangyong Heritage:

SsangYong Motor Company has a history dating back to 1954, initially involved in military vehicle production. Known for producing rugged, utility-focused vehicles, often utilizing technology licensed from other manufacturers (notably Mercedes-Benz for powertrains in early models).

Model Evolution

Rexton Evolution:

The Rexton series represents SsangYong's flagship SUV. The Rexton I (RJ platform, 2001-2006) was the first generation, built on a robust ladder frame chassis. The Rexton II (Y250 platform, 2006-2012) introduced updated styling and improved technology, often featuring Mercedes-Benz derived engines and transmissions. The Rexton W (also Y250 platform, 2012-2017) brought further styling revisions and powertrain updates. This manual covers this entire generational span.

Production

Manufacturing Locations:

Primarily South Korea (Pyeongtaek).

🏆 Awards & Recognition

Recognitions

Awards And Recognition:

SsangYong Rexton has received varied reviews over its production run, with common praise for its value proposition, off-road capability, and robustness, while criticism often focused on interior refinement, fuel economy (especially older diesel engines), and dealer network compared to mainstream brands.