🏷️ Basic Information

Make:

Ssangyong

Model:

Rexton

Model Code:

Y200

Production Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Positioning:

The Ssangyong Rexton Y200 was positioned as a rugged and capable SUV, often competing in the mid-size to large SUV segment, known for its robust construction and utility, particularly in off-road or towing scenarios.

Competitors:

Competed against vehicles like the Toyota Land Cruiser Prado, Mitsubishi Pajero/Montero Sport, Hyundai Terracan, and similar body-on-frame SUVs of its era.

Body Style:

5-door SUV with a ladder-frame chassis, emphasizing durability and towing capability.

Chassis Type:

Body-on-frame construction, derived from Mercedes-Benz technologies, providing robustness.

Drive Type:

Available in 2WD (rear-wheel drive) and 4WD (four-wheel drive) configurations, often with selectable or full-time 4WD systems.

Target Audience:

Mechanics and DIY enthusiasts seeking to perform maintenance, diagnostics, and repairs on the Ssangyong Rexton Y200.

📋 Manual Details

Primary Coverage:

Workshop Service Repair

Total Pages:

1991

Type:

Workshop Service Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Comprehensive diagnosis, testing, removal, installation, disassembly, assembly, and adjustment procedures for all engine variants used in the Y200 Rexton.

Transmission:

Detailed service procedures for both manual and automatic transmissions, including clutch, gear selection, diagnostics, fluid specifications, and rebuild information.

Drivetrain:

Coverage includes front and rear differentials, transfer case, drive shafts, axles, CV joints, and wheel bearings.

Suspension:

Complete procedures for front and rear suspension components, including shock absorbers, springs, control arms, bushings, and alignment specifications.

Steering:

Service and repair of the power steering system, steering rack, tie rods, and steering column.

Brakes:

Detailed information on hydraulic brake systems, including ABS, brake lines, master cylinder, calipers, brake pads, rotors, and bleeding procedures.

Electrical System:

Extensive coverage of the vehicle's electrical system, including battery, alternator, starter, lighting, ignition, and wiring diagrams for all circuits.

Body And Chassis:

Procedures for body panel removal and installation, interior trim, door mechanisms, glass, and structural components.

Cooling System:

Service and repair of the radiator, cooling fan, water pump, thermostat, and heater core.

Fuel System:

Diagnosis and repair of the fuel tank, fuel pump, fuel injectors, fuel filter, and emission control systems.

Exhaust System:

Information on exhaust manifold, catalytic converter, mufflers, and exhaust pipes.

Air Conditioning And Heating:

Service, repair, and recharging of the A/C system, as well as heating system components.

Interior Systems:

Procedures for seats, airbags, seatbelts, dashboard, and other interior components.

Maintenance:

Detailed periodic maintenance schedules, fluid checks, filter replacements, and general upkeep procedures.

Troubleshooting:

Extensive troubleshooting guides for common and uncommon issues, including diagnostic flowcharts and symptom-based problem resolution.

Repair:

Comprehensive, step-by-step repair procedures for virtually all mechanical and electrical components of the vehicle.

Disassembly And Assembly:

Detailed instructions for disassembling and reassembling vehicle components for repair or replacement.

Adjustments:

Specific instructions for making adjustments to various systems, such as engine timing, brake adjustments, and suspension alignment.

Technical Specifications:

Inclusion of all necessary technical specifications, including torque values, clearances, fluid capacities, and measurement specifications.

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems, aiding in troubleshooting and repair of electrical faults.

Diagnostic Procedures:

Provides guidance on diagnostic trouble codes (DTCs) and systematic troubleshooting methods for various electronic control units (ECUs).

Replacement Procedures:

Detailed instructions for replacing all major components, from minor sensors to large assemblies like the engine or transmission.

Special Tool References:

References specific Ssangyong or OEM special service tools required for particular repair operations, often accompanied by illustrations of the tools in use.

Tightening Torques:

Provides precise tightening torque specifications for critical fasteners across all vehicle systems to ensure proper assembly and safety.

Wear Limits:

Specifies allowable wear limits for various components, enabling technicians to accurately determine when parts need replacement.

Safety Precautions:

Includes explicit safety warnings, cautions, and notes (DANGER, CAUTION, NOTE) for procedures that carry inherent risks, emphasizing personal safety and preventing vehicle damage.

Depth Of Coverage:

From basic maintenance and routine service to complex engine rebuilds, drivetrain overhauls, and electrical system diagnostics.

Completeness:

The manual is described as 100% complete and intact, with no missing or corrupt pages, ensuring comprehensive coverage for all repair and maintenance needs.

📊 Manual Specifications

Print Quality:

Printable pages ensure clarity for on-site use. High resolution for clear text and diagrams.

Searchability:

PDF format allows for keyword searching, greatly improving efficiency in locating specific information.

Binding Type:

Digital (PDF) - Instant Download. Printable.

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Options:

Primarily powered by Mercedes-Benz-derived diesel engines, including the 2.7L (OM664) and 2.9L (OM602) inline-five cylinder engines. Some markets may have also featured petrol engines, though less common.

Horsepower Range:

Typically ranging from approximately 100 HP to 160 HP, depending on the specific engine variant and tuning.

Torque Range:

Torque figures generally range from 250 Nm to 340 Nm, providing strong low-end grunt suitable for towing and off-roading.

Injection Type:

Direct injection (diesel), with rotary or common rail fuel injection systems depending on the specific engine.

🔧 Transmission

Transmission Types:

Offered with both 5-speed manual transmissions and 4-speed or 5-speed automatic transmissions.

Optional Transmissions:

Automatic transmission was often an option over the standard manual.

Transfer Case:

4WD models typically feature a 2-speed transfer case with low-range gearing for enhanced off-road capability.

📐 Dimensions

Length:

Approximately 4700-4750 mm

Width:

Approximately 1870-1880 mm

Height:

Approximately 1700-1750 mm

Wheelbase:

Approximately 2730 mm

Curb Weight:

Typically around 1900-2100 kg, varying with configuration.

Gross Vehicle Weight Rating:

Around 2600-2800 kg.

🛡️ Safety Features

Crash Test Results:

Information on specific crash test ratings for the Y200 generation in various global markets would be detailed in manufacturer-specific safety reports and is not universally standardized. However, being a body-on-frame SUV, its structure is generally robust.

ABS:

Anti-lock Braking System (ABS) typically standard on most variants.

Traction Control:

Traction Control System (TCS) may be available on higher trim levels or 4WD models.

Airbags:

Front driver and passenger airbags are standard.

Seatbelts:

Pre-tensioning seatbelts for front occupants.

Child Seat Anchors:

ISOFIX child seat mounting points.

💡 Technology Features

Audio System:

Standard AM/FM radio with CD player and possibly cassette. Upgrade options may include multi-disc changers or premium sound systems on higher trims.

Navigation:

Optional factory-fitted GPS navigation systems were available on some models, though less common than in modern vehicles.

Cruise Control:

Cruise control was a common feature, particularly on higher specification models.

Auxiliary Input:

May feature an auxiliary audio input for connecting external devices.

🔧 Maintenance

Oil Change Interval:

Typically recommended every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type. Check manual for exact interval.

Timing Belt Replacement:

Diesel engines typically utilize timing chains or have specific replacement intervals for timing belts. For engines with belts, typically around 100,000 km or 5-7 years. Check manual.

Engine Oil:

Refer to manual for specific API/ACEA ratings and viscosity grades (e.g., 10W-40, 15W-40 for diesel engines, or synthetic oils as recommended).

Transmission Fluid:

Specific ATF fluid for automatic transmissions (e.g., Dexron III or equivalent) and manual transmission fluid (e.g., GL-4 or GL-5 gear oil) as per manual. Transfer case and differential fluids also specified.

Coolant:

Ethylene glycol-based antifreeze/coolant with appropriate corrosion inhibitors. Typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on system requirements.

Common Wear Items:

Potential for wear on suspension components (bushings, ball joints), exhaust system corrosion, and occasional issues with electronic sensors common in vehicles of this era. EGR valve clogging on diesel engines.

Engine Specific:

Some Mercedes-derived diesel engines can be very robust, but maintenance of fuel injection systems and turbochargers is critical. Glow plug issues can affect cold starts.

📚 Vehicle History

Brand Focus:

Ssangyong, a South Korean manufacturer, has historically focused on producing SUVs and commercial vehicles, often leveraging technology from established European automakers.

Origins:

The Rexton Y200 was Ssangyong's flagship SUV, developed with significant technical input and shared components from Mercedes-Benz, particularly its diesel engines and driveline technology.

Manufacturing Location:

Primarily manufactured in South Korea.

🏆 Awards & Recognition

Awards:

Specific industry awards for the Ssangyong Rexton Y200 are not widely publicized in major global automotive award circuits. Its recognition often stems from its value proposition as a capable and durable SUV for its price point.