SSANGYONG REXTON 2006.09 User manual

VEHICLE GENERAL
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VEHICLE GENERAL
VEHICLE GENERAL
1. DIMENSIONS........................................
2. SPECIFICATIONS.................................
3. VEHICLE IDENTIFICATION...................
4. MAINTENANCE ....................................
5. RECOMMENDED FLUIDS AND
LUBRICANTS........................................
6. JACK-UP POINTS (DOTTED CIRCLES).
7. PIN ARRANGEMENT OF DIAGNOSTIC
CONNECTOR........................................
8. ELECTRIC COMPONENTS AND
LAYOUT................................................
9. TIGHTENING TORQUE OF
STANDARD BOLTS...............................
3
4
6
7
13
14
15
16
18

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VEHICLE GENERAL
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EHICLE GENERAL
GENERAL
1. DIMENSIONS

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VEHICLE GENERAL
2. SPECIFICATIONS
* ( ): Optional, [ ]: 2WD, D27DTP: Diesel 2.7 Power-Up, D27DT: Diesel 2.7, G32D: Gasoline

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VEHICLE GENERAL
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VEHICLE GENERAL
3. VEHICLE IDENTIFICATION
1. Engine Number
Gasoline Engine: The engine
number is stamped on the
lower area of cylinder block in
exhaust manifold side.
Diesel Engine (D27DTP, D27DT):
The engine number is stamped on
the lower area of cylinder block
behind the Intake manifold.
2. Chassis Number
The chassis number is stamped on
the frame behind the front right tire.
3. Certification Label
The certification label is
located on the driver's door
sill.

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VEHICLE GENERAL
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4. MAINTENANCE
1) Diesel Engine * Use only approved Ssangyong genuine parts.
Maintenance service and record retention are the owner's responsibility. You should retain
evidence that proper maintenance has been performed on your vehicle in accordance with
the scheduled maintenance service chart.
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
ENGINE CONTROL SYSTEM
NOTE 1:
Adjust as required; - When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or
replace.
R - Replace or change.
(1)* If vehicle is operated under severe condition:
- Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving
distance below 16 km when the outside temperature remains below freezing
- Driving in a hilly or mountainous terrain, sandy, or dusty area
- High load driving such as trailer towing
- Taxi, patrol service or delivery service (extended idling and excessive driving with
low speed)
Shorten the service interval. Inspect the engine oil at any time, occasionally, if necessary
refill the engine oil.
(2)* If vehicle is operated under severe condition, driving in dusty condition or sandy condition,
pollutant area or off-road driving, frequently inspect the air cleaner, if necessary, change
the air cleaner.
(3)* More frequent maintenance is required if under dusty driving condition.
(4)* Refer to " Recommended fluids, coolant and lubricants".
* Water separator: When replace the engine oil, also drain the water from the fuel filter.

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VEHICLE GENERAL
CHASSIS AND BODY
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust
or replace.
R - Replace or change.
(3)* Refer to "Recommended fluids and lubricants".
(4)* More frequent maintenance is required if the vehicle is operated under any of the
following conditions:
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or higher, or
- In hilly or moutainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(5)* Inspect manual transmission fluid every 15,000 km (Inspect the leak of fluid at any
time,occasionally), then change every 60,000 km
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly driven
under severe conditions: Towing a trailer or off-road driving (Inspect the leak of fluid at
any time, occasionlly)

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VEHICLE GENERAL
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CHASSIS AND BODY
* Use only approved Ssangyong genuine parts.
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust
or replace.
R - Replace or change.
(3)* Refer to "Recommended fluids and lubricants".
(6)* After completion of off-road operation, the underbody of the vehicle should be throughly
inspected. Examine threaded fasteners for looseness.
(7)* If necessary, rotate and balance wheels.
(8)* After completion of off-road operation, the drive shaft boots should be inspected.
(9)* Inspect propeller shaft grease every 5,000 km or 3 months if the vehicle is mainly
driven under severe condition.
- In off-road or dusty road, or
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higher, or
- In hilly or moutainous terrain.
Severe Conditions in Air Conditioner Filter
- Pollutant area or off-road driving, extended air conditioner or heater operation

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VEHICLE GENERAL
2) Gasoline Engine * Use only approved Ssangyong genuine parts.
Maintenance service and record retention are the owner's responsibility. You should retain
evidence that proper maintenance has been performed on your vehicle in accordance with
the scheduled maintenance service chart.
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
ENGINE CONTROL SYSTEM
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
** - In order to secure engine long life and effective break-in, first oil (factory filled) would be
recommended to drain with in 10,000 km.
(1)* If vehicle is operated under severe condition: short distance driving, extensive idling or
driving in dusty condition, shorten the service interval.
(2)* If vehicle is operated under severe condition, pollutant area or off-road driving, driving
in dusty condition or sandy condition, frequently inspect the air cleaner, if necessary,
change the air cleaner.
(3)* Refer to "Recommended fluids and lubricants".

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VEHICLE GENERAL
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CHASSIS AND BODY
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or
replace.
R - Replace or change.
(3)* Refer to "Recommended fluids and lubricants".
(4)* More frequent maintenance is required if the vehicle is operated under any of the
following conditions:

higher, or
- In hilly or moutainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(5)* Inspect manual transmission fluid every 15,000 km (Inspect the leak of fluid at any
time,occasionally), then change every 60,000 km
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly
driven under severe conditions: Towing a trailer or off-road driving (Inspect the leak of
fluid at any time, occasionlly)

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VEHICLE GENERAL
CHASSIS AND BODY
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
Chart Symbols:
I -Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or
replace.
R - Replace or change.
(3)* Refer to "Recommended fluids and lubricants".
(6)* After completion of off-road operation, the underbody of the vehicle should be throughly
inspected. Examine threaded fasteners for looseness.
(7)* If necessary, rotate and balance wheels.
(8)* Inspect propeller shaft grease every 5,000 km or 3 months if the vehicle is mainly driven
under severe condition.
- In off-road or dusty road, or

higher, or
- In hilly or moutainous terrain.
Severe Conditions in Air Conditioner Filter
- Pollutant area or off-road driving, extended air conditioner or heater operation

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VEHICLE GENERAL
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5. RECOMMENDED FLUIDS AND LUBRICANTS
- Use only Ssangyong recommended fluids and lubricants.
- Keep the specified levels when adding or replacing the fluids.
- Do not mix any different types or brands of oils or fluids. This may cause damages.
D27DTP: Diesel 2.7 Power-Up
D27DT: Diesel 2.7
G32D: Gasoline

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VEHICLE GENERAL
IRS type
5-link type
6. JACK-UP POINTS (DOTTED CIRCLES)

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VEHICLE GENERAL
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7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR
It is installed under the instrument panel and consists of 16 pins.
The REKES key coding should be performed with SCAN-TOOLS.
Functions of Terminal
Diagnostic connector

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VEHICLE GENERAL
8. ELECTRIC COMPONENTS AND LAYOUT
1) Wiring Harness Arrangement

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VEHICLE GENERAL
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2) Components Locator

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VEHICLE GENERAL
9. TIGHTENING TORQUE OF STANDARD BOLTS
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Metric bolt strength is embossed on the
head of each bolt. The strength of bolt
can be classified as 4T, 7T, 8.8T, 10.9T,
11T and 12.9T in general.
Observe standard tightening torque
during bolt tightening works and can
adjust torque to be proper within 15 % if
necessary. Try not to over max. allowable
tightening torque if not required to do so.
1.
2.
Determine extra proper tightening torque
if tightens with washer or packing.
If tightens bolts on the below materials,
be sure to determine the proper torque.
3.
4.
Aluminum alloy: Tighten to 80 % of
above torque table.
Plastics: Tighten to 20 % of above
torque table.
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ENGINE ASSEMBLY
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ENGINE ASSEMBLY
GENERAL
1. DESCRIPTION AND OPERATION
1) Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten-thousanths of an inch.
When any internal engine parts are serviced, care and cleanliness are important.
A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and
lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces
and friction areas is part of the repair procedure.
This is considered standard shop practice even if not specifically stated.
Whenever valve train components are removed for service, they should be kept in order. They
should be installed in the same locations, and with the same mating surfaces, as when they
were removed.
Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to wire harness or other electrical parts.

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ENGINE ASSEMBLY
2) On-engine Service
Disconnect the negative battery cable before removing or installing any electrical unit, o
r
when a tool or equipment could easily come in contact with exposed electrical terminals.
Disconnecting this cable will help prevent personal injury and damage to the vehicle. The
ignition must also be in LOCK unless otherwise noted.
-
Any time the air cleaner is removed, the intake opening should be covered. This will
protect against accidental entrance of foreign material, which could follow the intake
passage into the cylinder and cause extensive damage when the engine is started.
-