Ssangyong Rexton Y200 2001-2006 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Rexton Model Code: Y200 Production Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Vehicle Class: Mid-size SUV / Off-road vehicle Competitive Analysis Key Competitors Era: Mitsubishi Pajero Sport, Hyundai Terracan, Kia Sorento, Isuzu Trooper (depending on market) Key Features Manual Value Proposition: Inexpensive way to keep the vehicle working properly, offering detailed, printable repair information. Manual Content Highlights: Detailed illustrations, diagrams, wiring schematics, specifications, and step-by-step instructions. Manual Organization: Numbered table of contents for quick information retrieval. 📋 Manual Details Coverage Areas Vehicle Make: SsangYong Vehicle Model: Rexton Y200 Vehicle Years: 2001-2006 Page Count Estimated Pages: Comprehensive (Exact count not specified, but implied extensive based on coverage) Manual Type Type: Workshop Service Repair Manual / Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed coverage including disassembly, inspection, assembly, and specifications. Engine Electrical: Includes diagnostics, component testing, and wiring schematics. Emission Control: Information on emission systems and related components. Fuel System: Covers fuel delivery, injection, and management systems. Suspension System: Front and rear suspension components, alignment, and repair procedures. Clutch System: Information on clutch operation, maintenance, and repair for manual transmissions. Manual Transaxle: Detailed repair and overhaul procedures for manual transmissions. Automatic Transaxle: Comprehensive coverage of automatic transmission operation, diagnostics, and repair. Driveshaft And Axle: Maintenance and repair of driveshafts, differentials, and axles. Steering System: Power steering, steering column, and linkage components. Brake System: Hydraulic and mechanical brake systems, including ABS. Body Interior Exterior: Body panels, trim, interior components, and cosmetic repairs. Body Electrical: Wiring diagrams and troubleshooting for body electrical components (lights, accessories, etc.). Restraint System: Airbag systems, seatbelts, and related safety components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and routine inspections. Diagnostics: Troubleshooting guides, symptom-based...

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Sku: 202075

Collections: ALL Ssangyong

Availability: 9999 in stock

Tags: 2001 2002 2003 2004 2005 2006 Car Cars Rexton Rexton Y200 Ssangyong

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Description

🏷️ Basic Information

Identification

Make:

SsangYong

Model:

Rexton

Model Code:

Production Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Market Position

Vehicle Class:

Mid-size SUV / Off-road vehicle

Competitive Analysis

Key Competitors Era:

Mitsubishi Pajero Sport, Hyundai Terracan, Kia Sorento, Isuzu Trooper (depending on market)

Key Features

Manual Value Proposition:

Inexpensive way to keep the vehicle working properly, offering detailed, printable repair information.

Manual Content Highlights:

Detailed illustrations, diagrams, wiring schematics, specifications, and step-by-step instructions.

Manual Organization:

Numbered table of contents for quick information retrieval.

📋 Manual Details

Coverage Areas

Vehicle Make:

SsangYong

Vehicle Model:

Rexton Y200

Vehicle Years:

2001-2006

Page Count

Estimated Pages:

Comprehensive (Exact count not specified, but implied extensive based on coverage)

Manual Type

Type:

Workshop Service Repair Manual / Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed coverage including disassembly, inspection, assembly, and specifications.

Engine Electrical:

Includes diagnostics, component testing, and wiring schematics.

Emission Control:

Information on emission systems and related components.

Fuel System:

Covers fuel delivery, injection, and management systems.

Suspension System:

Front and rear suspension components, alignment, and repair procedures.

Clutch System:

Information on clutch operation, maintenance, and repair for manual transmissions.

Manual Transaxle:

Detailed repair and overhaul procedures for manual transmissions.

Automatic Transaxle:

Comprehensive coverage of automatic transmission operation, diagnostics, and repair.

Driveshaft And Axle:

Maintenance and repair of driveshafts, differentials, and axles.

Steering System:

Power steering, steering column, and linkage components.

Brake System:

Hydraulic and mechanical brake systems, including ABS.

Body Interior Exterior:

Body panels, trim, interior components, and cosmetic repairs.

Body Electrical:

Wiring diagrams and troubleshooting for body electrical components (lights, accessories, etc.).

Restraint System:

Airbag systems, seatbelts, and related safety components.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, and routine inspections.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, and fault code interpretation.

Repair:

Step-by-step instructions for component removal, repair, and installation.

Rebuild:

Engine and transmission overhaul procedures.

Wiring Schematics:

Comprehensive electrical wiring diagrams for all systems.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to major component overhaul and complex diagnostics.

Target Audience:

Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Fully printable, allowing users to print specific sections or the entire manual.

Zoom Capability:

Yes, zoom in/out for detailed viewing of illustrations and diagrams.

Binding Type

Binding:

Digital (PDF)

Paper Type

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine Options

Engine Type Diesel:

Likely Mercedes-Benz derived diesel engines (e.g., OM601, OM602 variants) or SsangYong's own XDi common rail diesels.

Engine Type Petrol:

Likely Mercedes-Benz derived petrol engines (e.g., M162, M111 variants) or SsangYong's own petrol engines.

Performance

Horsepower Range:

Typically 120-170 HP for diesel and 150-200 HP for petrol variants, depending on specific engine.

Torque Range:

Approximately 250-350 Nm for diesel and 200-250 Nm for petrol variants.

Fuel System

Fuel Injection Diesel:

Common Rail Direct Injection (CRDI) or older indirect injection systems.

Fuel Type:

Diesel and Unleaded Petrol

🔧 Transmission

Standard Transmission

Manual Gearbox:

Likely 5-speed manual transmission.

Optional Transmission

Automatic Gearbox:

Likely 4-speed or 5-speed automatic transmission, potentially sourced from Mercedes-Benz.

Features

Drivetrain:

Part-time 4WD system with low-range gearing, often with electronic or manual engagement.

📐 Dimensions

Exterior

Body Style:

5-door SUV

Wheelbase:

Approx. 2830 mm

Length:

Approx. 4650 mm

Width:

Approx. 1870 mm

Height:

Approx. 1780 mm

Weights

Curb Weight:

Approx. 1800-2000 kg, depending on engine and configuration.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited publicly available official crash test data for this specific generation in major global NCAP programs.

Active Features

Standard on most models, with EBD (Electronic Brakeforce Distribution).

Passive Features

Airbags:

Front airbags for driver and passenger. Side airbags may be optional on higher trims.

Seatbelts:

Pre-tensioner seatbelts for front occupants.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with CD player, optional cassette player. Speaker configurations vary by trim level.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Connectivity

Auxiliary Input:

May be present on later models or as an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used.

Timing Belt Replacement:

For applicable engines, usually around 80,000-120,000 km or 5-7 years. Diesel models with timing chains may not have this requirement.

Fluid Specifications

Engine Oil Type:

API CD/CE/CF for older diesels, API SJ/SL for petrol. Viscosity SAE 15W-40, 10W-30, or 5W-30 depending on climate and specific engine oil recommendation. Consult manual for exact specs.

Transmission Fluid Automatic:

Mercon V or Dexron III/VI equivalent, or Mercedes-Benz approved ATF. Consult manual for exact specification.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Consult manual for exact specification.

Coolant Type:

Ethylene glycol-based coolant, typically a green or orange type depending on manufacturer specification. Mixture of 50/50 coolant and distilled water.

Known Issues

Common Problems:

Potential issues can include turbocharger problems on diesel engines, suspension component wear (bushings, ball joints), minor electrical gremlins, and exhaust gas recirculation (EGR) valve issues on diesels. Rust can also be a concern in certain climates.

📚 Vehicle History

Brand Heritage

Ssangyong Origin:

South Korean manufacturer with a history of producing robust SUVs and commercial vehicles, often utilizing Mercedes-Benz technology.

Model Evolution

Rexton Y200 Genesis:

The first generation Rexton (Y200) was launched in 2001, based on a Mercedes-Benz M-Class (W163) platform and often using Mercedes-Benz derived powertrains.

Production

Manufacturing Location:

Primarily South Korea.

🏆 Awards & Recognition

Recognitions

Market Reception:

Generally considered a budget-friendly alternative in the SUV market, offering strong towing and off-road capability for its price point.