Ssangyong Rexton Y200 2001-2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Model Code: Y200 Generation Generation: First Generation Codes Production Years: 2001-2006 👋 Introduction Market Position Positioning: The SsangYong Rexton Y200, launched in 2001, was positioned as a rugged and capable large SUV, often competing in markets with other body-on-frame SUVs like the Toyota Land Cruiser Prado, Mitsubishi Pajero, and Chevrolet TrailBlazer. It aimed to offer a blend of off-road prowess and comfortable on-road cruising. Competitive Analysis Comparisons: Key competitors in its segment during its production run included vehicles with similar body-on-frame construction, robust diesel engine options, and substantial towing capacities. Its distinctive styling and Korean origin often set it apart. Key Features Vehicle Highlights: Body-on-frame construction for durability, robust engine options (often including diesel), available 4WD systems, spacious interior, and significant towing capability. Manual Value Proposition Benefits For Owner: Empowers owners and independent mechanics to perform comprehensive maintenance and repairs, saving on dealership costs. Provides in-depth understanding for troubleshooting and emergency repairs, increasing self-reliance. Accessibility: Information is presented with a table of contents for easy navigation, minimizing stress in locating necessary repair or maintenance data. 📋 Manual Details Coverage Areas Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Thousands (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF (Digital Download) Software Requirements: Requires Adobe PDF Reader and WinZip for extraction and viewing. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, emissions control. Transmission: Automatic and Manual Transmission systems, including operation, diagnostics, repair, and overhaul. Drivetrain: Front-wheel drive, rear-wheel drive, 4x4 (4WD) systems, differentials, drive shafts, CV joints. Chassis & Suspension: Front and rear suspension components, steering system, wheel bearings, alignment specifications. Brakes: Hydraulic brake system, ABS (Anti-lock...

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton

Model Code:

Generation

Generation:

First Generation

Codes

Production Years:

2001-2006

👋 Introduction

Market Position

Positioning:

The SsangYong Rexton Y200, launched in 2001, was positioned as a rugged and capable large SUV, often competing in markets with other body-on-frame SUVs like the Toyota Land Cruiser Prado, Mitsubishi Pajero, and Chevrolet TrailBlazer. It aimed to offer a blend of off-road prowess and comfortable on-road cruising.

Competitive Analysis

Comparisons:

Key competitors in its segment during its production run included vehicles with similar body-on-frame construction, robust diesel engine options, and substantial towing capacities. Its distinctive styling and Korean origin often set it apart.

Key Features

Vehicle Highlights:

Body-on-frame construction for durability, robust engine options (often including diesel), available 4WD systems, spacious interior, and significant towing capability.

Manual Value Proposition

Benefits For Owner:

Empowers owners and independent mechanics to perform comprehensive maintenance and repairs, saving on dealership costs. Provides in-depth understanding for troubleshooting and emergency repairs, increasing self-reliance.

Accessibility:

Information is presented with a table of contents for easy navigation, minimizing stress in locating necessary repair or maintenance data.

📋 Manual Details

Coverage Areas

Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

Page Count

Estimated Page Count:

Thousands (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

Software Requirements:

Requires Adobe PDF Reader and WinZip for extraction and viewing.

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, emissions control.

Transmission:

Automatic and Manual Transmission systems, including operation, diagnostics, repair, and overhaul.

Drivetrain:

Front-wheel drive, rear-wheel drive, 4x4 (4WD) systems, differentials, drive shafts, CV joints.

Chassis & Suspension:

Front and rear suspension components, steering system, wheel bearings, alignment specifications.

Brakes:

Hydraulic brake system, ABS (Anti-lock Braking System), parking brake, brake fluid specifications.

Electrical:

12-volt electrical system, battery, alternator, starter, lighting systems, fuses, relays, wiring diagrams.

Body & Interior:

Body panels, doors, glass, seats, interior trim, HVAC (Heating, Ventilation, and Air Conditioning) system.

Diagnostics:

On-Board Diagnostics (OBD-II) systems, trouble codes (DTCs), diagnostic procedures.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system service, including refrigerant handling, component diagnosis, and repair of the compressor, evaporator, condenser, and blower motor.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, and fuel filter servicing and replacement.

Ignition System:

Spark plugs, ignition coils, and related components for gasoline engines; glow plugs and control modules for diesel engines.

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, tune-ups.

Troubleshooting:

Step-by-step diagnostic guides for common and complex issues.

Repair:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Specifications:

Torque specifications, clearances, measurements, electrical resistance values.

Wiring Diagrams:

Comprehensive electrical circuit diagrams for all vehicle systems.

Body Repair:

Procedures for body panel alignment, dent repair, rust prevention, and exterior trim replacement.

Interior Repair:

Instructions for interior trim panel removal, upholstery repair, and dashboard component access.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks and adjustments to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications required for professional-level repairs.

Diagnostic Tools:

Guidance on the use of specialized diagnostic tools and scan equipment relevant to the Rexton Y200's ECUs.

📊 Manual Specifications

File Format

Digital Format:

Compatibility:

Compatible with all versions of Windows & Mac operating systems.

Print Quality

Clarity:

High resolution for clear text and diagrams; searchable text for easy navigation.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Options:

Likely offered with 2.7L Mercedes-Benz-derived diesel engines (e.g., the RDi 270 XDi, XDi) and potentially 3.2L gasoline engines. Specific engine codes (e.g., OM662LA for diesel) would be detailed in the manual.

Performance

Horsepower Range:

Diesel variants typically ranged from 120-165 hp, while gasoline variants would be higher. Torque figures would be substantial for diesel models.

Fuel System

Injection Type:

Direct Injection (DI) for diesel engines, likely with common rail technology in later models. Gasoline engines would feature multi-point fuel injection (MPI) or similar.

Engine Management

ECU Details:

Engine Control Unit (ECU) specifications, sensor data, and diagnostic parameters will be covered.

Emissions Control:

Detailed information on emissions control systems, including catalytic converters, EGR (Exhaust Gas Recirculation) systems, and related sensors and valves.

🔧 Transmission

Standard

Transmission Types:

Likely equipped with a 5-speed manual transmission and a 4-speed or 5-speed automatic transmission.

Optional

Transmission Options:

While not explicitly stated as 'optional' in the product description, different transmission types (manual vs. automatic) were likely available depending on the trim level and market.

Features

Drivetrain Modes:

Details on the operation and servicing of part-time or full-time 4WD systems will be included.

📐 Dimensions

Exterior

Dimensions:

Exact dimensions would vary by specific model year and configuration, but it was a full-size SUV, typically around 4700-4800mm in length, 1800-1850mm in width, and 1750-1800mm in height.

Weights

Curb Weight:

Curb weights would typically range from 1900 kg to 2100 kg, depending on engine and drivetrain configuration.

🛡️ Safety Features

Ratings

Crash Test Results:

While specific official crash test ratings (like Euro NCAP or NHTSA) for this model in all markets might be limited, the manual would detail structural integrity and safety system performance.

Active Features

Active Safety:

Likely included ABS (Anti-lock Braking System), potentially EBD (Electronic Brakeforce Distribution), and traction control systems in higher trims.

Passive Features

Passive Safety:

Front airbags, side airbags (in some models), seatbelt pre-tensioners, and reinforced passenger cell construction.

💡 Technology Features

Infotainment

Audio System:

Base to premium audio systems, likely featuring AM/FM radio, CD player, and potentially cassette player. Speaker configurations and head unit removal/installation procedures would be covered.

Driver Assistance

Cruise Control:

Operation, diagnosis, and repair of the cruise control system.

Connectivity

Power Accessories:

Details on power windows, power door locks, power mirrors, and seat adjustments.

🔧 Maintenance

Service Intervals

Recommended Intervals:

Typical intervals for oil changes (e.g., 5,000-7,500 miles or 6-12 months), air filters, fuel filters, and other fluids would be detailed in the manual.

Timing Belt Or Chain:

Information regarding timing belt replacement intervals (if applicable) or the inspection of timing chains.

Fluid Specifications

Engine Oil:

Specific API and viscosity grades (e.g., API CI-4 or CH-4 for diesel, API SL/SM for gasoline, with viscosities like 5W-30 or 10W-40) would be provided. Engine oil capacity would also be listed.

Transmission Fluid:

Specifications for automatic transmission fluid (ATF, e.g., Dexron III/Mercon) and manual transmission fluid (gear oil, e.g., GL-4 or GL-5) with appropriate viscosity grades.

Coolant:

Type of coolant (e.g., ethylene glycol based) and specific mixture ratios (e.g., 50/50 with distilled water).

Brake Fluid:

DOT 3 or DOT 4 brake fluid specifications.

Known Issues

Common Problems:

Common issues might include issues related to older diesel engine components (e.g., glow plugs, injectors, turbocharger wear), automatic transmission solenoids, and potential electronic sensor failures. The manual is crucial for diagnosing and rectifying these.

Filters

Filter Part Numbers:

While specific part numbers are not provided here, the manual would list them for oil filters, air filters, fuel filters, and cabin air filters.

📚 Vehicle History

Brand Heritage

Ssangyong Background:

SsangYong Motor Company, a South Korean manufacturer, has a history dating back to 1954, often associated with robust utility vehicles and SUVs, frequently utilizing Mercedes-Benz technology and powertrains.

Model Evolution

Rexton Development:

The Rexton Y200 marked SsangYong's entry into the global large SUV market, built on a separate chassis platform. It was designed as a premium and capable off-road vehicle.

Production

Manufacturing Locations:

Primarily manufactured in South Korea.