Complete service repair manual for the 2001-2006 SsangYong Rexton Y200 SUV. Covers 2.9L Mercedes-Benz licensed turbo diesel engine overhaul, turbocharger service, transmission rebuild, transfer case overhaul, four-wheel drive system diagnostics, front double-wishbone suspension service, rear five-link suspension repair, CV joint and boot replacement, propeller shaft service, brake system overhaul, power steering repair, fuel injection pump calibration, cooling system maintenance, air conditioning service, body-to-frame mount inspection, and all routine service procedures with OEM specifications and diagnostic troubleshooting procedures.
The SsangYong Rexton Y200 is a body-on-frame mid-to-large SUV produced from 2001 through 2006 representing SsangYong Motor flagship off-road capable sport utility vehicle positioned against competitors like the Toyota Land Cruiser Prado and Nissan Patrol. The Rexton features a rugged ladder-frame chassis with independent double-wishbone front suspension and five-link coil-spring rear suspension delivering genuine four-wheel-drive capability with selectable transfer case and low-range gearing. Engine options included Mercedes-Benz sourced inline-four and inline-five diesel engines under license from DaimlerChrysler, specifically the OM662 2.9-liter turbo diesel producing approximately 130 horsepower and the OM602 2.3-liter variant. Transmission choices included a five-speed manual or automatic options with part-time four-wheel drive featuring two-speed transfer case. The Rexton offers genuine towing capability, spacious seven-seat configurations, and robust construction suited for both highway cruising and serious off-road terrain.
VEHICLE EQUIPMENT INTRODUCTION:
The SsangYong Rexton Y200 combines rugged body-on-frame construction with Mercedes-Benz licensed diesel power for genuine off-road capability and seven-seat family transport. Independent front suspension, five-link rear, selectable four-wheel drive with low range, and robust ladder-frame chassis deliver versatility across all terrain conditions.
SERVICE AND REPAIR SCOPE:
- Mercedes-Benz licensed 2.9L turbo diesel engine overhaul with head gasket service
- Turbocharger inspection with oil feed and return line service
- Five-speed manual transmission and automatic transmission rebuild
- Transfer case two-speed system inspection and shift linkage adjustment
- Front double-wishbone suspension upper and lower ball joint replacement
- Five-link rear suspension arm bushing and coil spring service
- Front axle CV joint inspection and boot replacement
- Propeller shaft universal joint and center support bearing service
- Brake system overhaul with front disc caliper and rear disc service
- Power steering pump seal replacement and rack inspection
- Fuel injection pump calibration and nozzle spray pattern test
- Engine cooling system water pump and thermostat service
- Air conditioning compressor clutch and condenser service
- Transfer case shift fork and synchronizer inspection
- Body-on-frame mount bolt torque and bushing compression check
TECHNICAL SPECIFICATIONS:
- Engine: 2.9L turbo diesel inline-4 (Mercedes-Benz OM662 licensed)
- Horsepower: Approximately 130 HP
- Torque: Approximately 220 lb-ft
- Transmission: 5-speed manual or 4-speed automatic
- Transfer case: Part-time 4WD, two-speed with low range
- Front suspension: Independent double-wishbone with coil springs
- Rear suspension: Five-link with coil springs
- Brakes: Front and rear ventilated discs
- Steering: Recirculating ball with power assist
- Seating: Up to 7 passengers
- Towing capacity: Substantial with factory tow package
DIAGNOSTIC INFORMATION:
- Turbo boost pressure verification at various engine speeds
- Injection pump timing adjustment and nozzle leak-off test
- Transfer case engagement failure from shift fork wear
- CV joint boot tear identification from grease splash pattern
- Propeller shaft vibration from worn U-joint or center bearing
- Front ball joint wear causing tire wear and wandering steering
- Fuel filter water contamination causing rough running
- Cooling fan clutch engagement assessment
ILLUSTRATIONS AND DIAGRAMS INCLUDED:
- Engine assembly with turbocharger and intake routing
- Fuel injection pump and injector layout
- Transfer case cross-section with shift mechanism
- Front double-wishbone suspension geometry
- Rear five-link suspension exploded view
- Electrical wiring diagram with sensor locations
- Brake hydraulic circuit detail
- Body-to-frame mounting point locations
COMPATIBILITY:
- Covers: 2001 2002 2003 2004 2005 2006 SsangYong Rexton Y200
- Mercedes-Benz OM662 2.9L turbo diesel engine
- Manual and automatic transmission variants
- Part-time four-wheel drive models
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
The SsangYong Rexton Y200 is a body-on-frame mid-to-large SUV produced from 2001 through 2006 representing SsangYong Motor flagship off-road capable sport utility vehicle positioned against competitors like the Toyota Land Cruiser Prado and Nissan Patrol. The Rexton features a rugged ladder-frame chassis with independent double-wishbone front suspension and five-link coil-spring rear suspension delivering genuine four-wheel-drive capability with selectable transfer case and low-range gearing. Engine options included Mercedes-Benz sourced inline-four and inline-five diesel engines under license from DaimlerChrysler, specifically the OM662 2.9-liter turbo diesel producing approximately 130 horsepower and the OM602 2.3-liter variant. Transmission choices included a five-speed manual or automatic options with part-time four-wheel drive featuring two-speed transfer case. The Rexton offers genuine towing capability, spacious seven-seat configurations, and robust construction suited for both highway cruising and serious off-road terrain.
VEHICLE EQUIPMENT INTRODUCTION:
The SsangYong Rexton Y200 combines rugged body-on-frame construction with Mercedes-Benz licensed diesel power for genuine off-road capability and seven-seat family transport. Independent front suspension, five-link rear, selectable four-wheel drive with low range, and robust ladder-frame chassis deliver versatility across all terrain conditions.
SERVICE AND REPAIR SCOPE:
- Mercedes-Benz licensed 2.9L turbo diesel engine overhaul with head gasket service
- Turbocharger inspection with oil feed and return line service
- Five-speed manual transmission and automatic transmission rebuild
- Transfer case two-speed system inspection and shift linkage adjustment
- Front double-wishbone suspension upper and lower ball joint replacement
- Five-link rear suspension arm bushing and coil spring service
- Front axle CV joint inspection and boot replacement
- Propeller shaft universal joint and center support bearing service
- Brake system overhaul with front disc caliper and rear disc service
- Power steering pump seal replacement and rack inspection
- Fuel injection pump calibration and nozzle spray pattern test
- Engine cooling system water pump and thermostat service
- Air conditioning compressor clutch and condenser service
- Transfer case shift fork and synchronizer inspection
- Body-on-frame mount bolt torque and bushing compression check
TECHNICAL SPECIFICATIONS:
- Engine: 2.9L turbo diesel inline-4 (Mercedes-Benz OM662 licensed)
- Horsepower: Approximately 130 HP
- Torque: Approximately 220 lb-ft
- Transmission: 5-speed manual or 4-speed automatic
- Transfer case: Part-time 4WD, two-speed with low range
- Front suspension: Independent double-wishbone with coil springs
- Rear suspension: Five-link with coil springs
- Brakes: Front and rear ventilated discs
- Steering: Recirculating ball with power assist
- Seating: Up to 7 passengers
- Towing capacity: Substantial with factory tow package
DIAGNOSTIC INFORMATION:
- Turbo boost pressure verification at various engine speeds
- Injection pump timing adjustment and nozzle leak-off test
- Transfer case engagement failure from shift fork wear
- CV joint boot tear identification from grease splash pattern
- Propeller shaft vibration from worn U-joint or center bearing
- Front ball joint wear causing tire wear and wandering steering
- Fuel filter water contamination causing rough running
- Cooling fan clutch engagement assessment
ILLUSTRATIONS AND DIAGRAMS INCLUDED:
- Engine assembly with turbocharger and intake routing
- Fuel injection pump and injector layout
- Transfer case cross-section with shift mechanism
- Front double-wishbone suspension geometry
- Rear five-link suspension exploded view
- Electrical wiring diagram with sensor locations
- Brake hydraulic circuit detail
- Body-to-frame mounting point locations
COMPATIBILITY:
- Covers: 2001 2002 2003 2004 2005 2006 SsangYong Rexton Y200
- Mercedes-Benz OM662 2.9L turbo diesel engine
- Manual and automatic transmission variants
- Part-time four-wheel drive models
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
