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...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton

Year Range:

2001-2003

Codes

Platform Code:

👋 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:

📖 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:

Width Mm Approx:

Height Mm Approx:

Wheelbase Mm Approx:

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, potential oil leaks from valve cover gasket, intake manifold leaks, MAF sensor issues.

Common Problems Diesel:

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.