SsangYong Rexton I II W 2001-2011 Workshop Repair Service Manual PDF - MSYRT0115OPES.zip
SsangYong Rexton All Models Workshop Repair Manual
This all-inclusive repair and service guide for every SsangYong Rexton model comes with full electrical wiring schematics, giving you the same workshop-level detail professionals rely on to maintain, troubleshoot, fix, and service the vehicle.
SsangYong Rexton I, Rexton II, Rexton W All Models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 22,742 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
2001-2006 Rexton.......1
ENGINE.......1
CHASSIS.......588
2001-2011 Rexton I-II.......1894
ENGINE.......1894
ENGINE ASSEMBLY.......1894
STRUCTURE AND FUNCTION DESCRIPTIONS.......1895
ENGINE PERFORMANCE CURVE.......1900
GENERAL DIAGNOSIS.......1902
DIAGNOSTIC INFORMATION AND PROCEDURE.......1907
COMPRESSION PRESSURE TEST.......1908
CYLINDER PRESSURE LEAKAGE TEST.......1910
TIGHTENING TORQUE.......1911
REMOVAL AND INSTALLATION.......1914
Engine Assembly - Removal.......1915
DISASSEMBLY AND REASSEMBLY.......1924
Inspection Before Disassembly and.......1925
Accessories - Removal and Installation.......1926
Engine - Disassembly and Reassembly.......1940
ENGINE HOUSING.......1954
CYLINDER HEAD/CYLINDER BLOCK.......1955
CAMSHAFT ASSEMBLY.......1969
TIMING CHAIN ASSEMBLY.......1977
CYLINDER BLOCK.......1981
CRANKSHAFT.......1984
ARRANGEMENT OF THRUST WASHERS AND BEARINGS.......1985
TORSIONAL VIBRATION DAMPER.......1990
Crankshaft - Disassembly.......1991
PISTON AND CONNECTING ROD.......1994
PISTON RING.......1995
CYLINDER INNER DIAMETER AND PISTON SIZE.......1996
Piston - Reassembly.......1997
HIGH PRESSURE PUMP (HPP).......2001
HP Pump - Disassembly and Reassembly.......2002
INTAKE SYSTEM.......2007
AIR FLOWS.......2008
INTAKE SYSTEM LAYOUT.......2009
AIR CLEANER.......2010
AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR).......2013
INTERCOOLER.......2019
INTAKE MANIFOLD ASSEMBLY.......2021
EXHAUST SYSTEM.......2026
EXHAUST SYSTEM LAYOUT.......2027
EXHAUST GAS FLOWS.......2028
TURBO CHARGER ASSEMBLY.......2030
EGR VALVE AND VACUUM MODULATOR.......2051
EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM.......2052
EXHAUST SYSTEM AND MUFFLER.......2060
SYSTEM OVERVIEW Exhaust System.......2061
LUBRICATION SYSTEM.......2067
LUBRICATION SYSTEM LAYOUT.......2069
LUBRICATION DIAGRAM.......2070
SPECIFICATIONS.......2071
ENGINE OIL CHANGE.......2075
OIL PUMP.......2079
OIL SPRAY NOZZLE.......2081
OIL PAN ASSEMBLY.......2082
TROUBLE DIAGNOSIS.......2083
SPECIAL TOOLS AND EQUIPMENT.......2084
COOLING SYSTEM.......2085
ENGINE COOLING SYSTEM.......2087
SPECIFICATIONS.......2097
INSPECTION AND REPAIR.......2098
REMOVAL AND INSTALLATION.......2100
PREHEATING SYSTEM.......2113
OVERVIEW.......2114
PREHEATING SYSTEM DIAGRAM.......2115
FUEL SYSTEM.......2117
CAUTIONS FOR DI ENGINE.......2118
FUEL INJECTION SYSTEM.......2121
FUEL TRANSFER LINE.......2127
INLET METERING VALVE (IMV).......2129
HIGH FUEL PRESSURE LINE.......2132
INJECTOR.......2163
ENGINE CONTROL SYSTEM.......2177
SENSORS FOR DIAGNOSIS.......2178
TOP VIEW.......2179
SIDE VIEW.......2180
ENGINE CONTROL SYSTEM.......2181
FUEL PRESSURE CONTROL.......2187
FUEL INJECSTION CONTROL.......2188
FUEL FLOW CONTROL.......2189
INDIVIDUAL INJECTOR CALIBRATION (C2I).......2194
MINIMUM DRIVE PULSE (MDP) LEARNING.......2196
Accelerator Pedal Sensor.......2197
ELECTRIC DEVICES.......2202
SENSORS IN ENGINE COMPARTMENT.......2203
ELECTRIC DEVICES IN ENGINE COMPARTMENT.......2204
SPECIFICATIONS.......2205
CIRCUIT DIAGRAM OF PREHEATING SYSTEM.......2206
CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR.......2207
TROUBLE DIAGNOSIS.......2208
ALTERNATOR.......2210
STARTER.......2212
PREHEATING SYSTEM.......2214
PREHEATING TIME RELAY.......2216
GLOW PLUG.......2217
SPECIAL TOOLS AND EQUIPMENT.......2219
GENERAL INFORMATION.......2220
CLEANNESS.......2221
STRUCTURE.......2226
ENGINE CONTROLS.......2229
ENGINE AND SENSORS.......2230
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM.......2231
INTAKE SYSTEM.......2232
LUBRICATION SYSTEM.......2236
COOLING SYSTEM.......2237
FUEL SYSTEM.......2239
GENERAL SPECIFICATIONS.......2241
MAINTENANCE.......2244
VEHICLE IDENTIFICATION.......2246
HOW TO USE AND MAINTAIN WORKSHOP MANUAL.......2248
GUIDELINES FOR SERVICE WORK SAFETY.......2249
LIFTING POINTS.......2254
TIGHTENING TORQUE OF STANDARD BOLTS.......2255
SCAN-I OPERATING PROCEDURES.......2256
FUNCTION SELECTION.......2259
Sensor Data Check.......2260
Actuator Check.......2261
Trouble Code Clear.......2263
ECU Identification.......2265
Injector Coding (C2I).......2266
Leak Detection.......2268
Variant Coding.......2269
ECU Replace.......2271
TROUBLE DIAGNOSIS TABLE.......2276
INDEX OF DTC.......2277
TROUBLE DIAGNOSIS TABLE.......2280
INDEX OF DTC.......2323
TROUBLE DIAGNOSIS PROCEDURES.......2327
Cam Position Sensor (missing event).......2328
Too Small Clearance of Crank Angle.......2330
Barometric Sensor Malfunction.......2333
Battery Voltage Monitoring Signal.......2334
Booster Pressure Sensor Malfunction.......2336
Brake Pedal Switch Malfunction.......2342
High Wiring Resistance (Injector #1).......2344
Clutch Switch Malfunction.......2349
Coolant Temperature.......2350
Too Fast or Low Main Relay Operation.......2352
EGR Actuator Malfunction.......2353
Condenser Fan Driving Signal Fault.......2354
#1 Accelerometer Malfunction.......2356
Injector Bank 1 Malfunction.......2358
Cylinder Balancing Fault (Injector #1) =.......2362
Open Circuit (Injector #1).......2367
Fuel Temperature Sensor Malfunction.......2377
Glow Plug Malfunction (Driving Signal).......2378
Heater 1 Malfunction (Driving Signal).......2379
Rail Pressure Control Fault.......2381
IMV Operation Fault (Electrical Fault).......2387
Intake Air Temperature Sensor Fault.......2388
MDP Fault (Injector #1).......2389
Rail Pressure Fault (Too High).......2392
Accelerator Pedal Sensor Malfunction.......2394
Fuel Rail Pressure Sensor Malfunction.......2400
Main Relay Malfunction - Stuck.......2404
Vehicle Speed Fault.......2405
5V Supply Voltage 1 Fault.......2406
Turbo Charger Actuator Operation Fault.......2409
ECU Watchdog Fault.......2410
Accelerometer Learning Fault.......2415
EGR Valve Control Fault.......2416
VGT Operation Fault.......2417
TBD.......2419
No Crank Signal.......2420
High Torque Trim.......2421
Glow Plug Module Communication Fault.......2422
TCU Signal Fault.......2425
Air Conditioner Operating Circuit Fault.......2426
Excessive Water in Fuel Filter.......2427
Immobilizer Malfunction.......2428
FUEL SYSTEM DIAGNOSIS.......2429
OVERVIEW.......2430
FUEL PRESSURE SYSTEM.......2431
FUEL SYSTEM PRESSURE TEST.......2434
FUEL SYSTEM CHECK PROCESS.......2436
PRESSURE LEAKAGE TEST WITH SCAN-100.......2445
CHASSIS.......2447
FFH/PTC SYSTEM.......2447
FUEL FIRED HEATER (FFH) SYSTEM.......2448
SYSTEM LAYOUT.......2449
TROUBLE DIAGNOSIS.......2458
REMOVAL AND INSTALLATION.......2470
POSITIVE TEMPERATURE COEFFICIENT (PTC) SYSTEM.......2475
COMPONENTS.......2476
CIRCUIT DIAGRAM.......2477
REMOVAL AND INSTALLATION.......2478
HEATER & VENTILATION.......2480
GENERAL INFORMATION.......2481
MANUAL AIR CONDITIONER.......2482
AUTOMATIC AIR CONDITIONER.......2485
AIR FLOWS THROUGH VENTS (MODE SWITCH OPERATIONS).......2490
SPECIFICATIONS.......2491
AIR DISTRIBUTION.......2492
CIRCUIT DIAGRAM.......2494
TROUBLE DIAGNOSIS.......2495
BLOWER ELECTRICAL.......2497
MAINTENANCE AND REPAIR.......2502
AIR DUCT ASSEMBLY.......2503
REAR COOLER DUCT.......2504
HEATER AND BLOWER MODULE.......2505
A/C SYSTEM.......2508
DESCRIPTION AND OPERATION.......2509
TROUBLE DIAGNOSIS.......2519
CHECK AND REPLACEMENT.......2526
REMOVAL AND INSTALLATION.......2531
DISASSEMBLY AND REASSEMBLY.......2537
MANUAL AIR CONDITIONING SYSTEM.......2539
TROUBLE DIAGNOSIS.......2542
REMOVAL AND INSTALLATION.......2545
AUTOMATIC AIR CONDITIONER SYSTEM.......2546
SPECIFICATIONS.......2557
TROUBLE DIAGNOSIS.......2558
REMOVAL AND INSTALLATION.......2573
BODY.......2579
GENERAL INFORMATION.......2580
SPECIFICATIONS.......2581
WATERLEAK TEST.......2582
GENERAL REPAIR.......2584
TROUBLE DIAGNOSIS.......2586
SPECIAL TOOLS AND EQUIPMENT.......2589
BODY DIMENSIONS.......2590
FRAME.......2591
SIDE STRUCTURE COMPLETE.......2592
ENGINE COMPARTMENT.......2594
WINDSHIELD AND TAILGATE GLASS.......2595
TAILGATE.......2596
GAP CHART.......2597
UNDERCOATING.......2599
BODY MOUNTINGS.......2600
WIRING HARNESS (DI ENGINE EQUIPPED VEHICLE).......2601
VEHICLE INTERIOR.......2615
SEAT.......2616
REMOVAL AND INSTALLATION.......2622
DISASSEMBLY AND REASSEMBLY.......2626
SEAT BELT.......2632
REMOVAL AND INSTALLATION.......2633
CONVENIENT DEVICES.......2638
OTHER COMPONENTS.......2641
INTERIOR TRIM AND ROOF ASSEMBLY.......2647
INSTRUMENT ASSEMBLY.......2652
EXTERIOR.......2657
COMPONENTS LOCATOR.......2658
TAILGATE.......2659
FLIP-UP SYSTEM.......2660
HOOD.......2662
SUN ROOF AND ROOF RACK.......2663
MOLDING.......2664
REMOVAL AND INSTALLATION.......2665
AIRBAG SYSTEM.......2732
GENERAL DESCRIPTION AND OPERATION.......2733
CAUTIONS WITH THE AIR BAG.......2734
FUNCTION DESCRIPTION.......2738
FRONT AIR BAG.......2741
SIDE AIR BAG.......2744
DC 5-SPEED AUTOMATIC.......2772
GENERAL INFORMATION.......2773
CHARACTERISTICS.......2774
STRUCTURE.......2775
PERFORMANCE CURVE AND GENERAL CHARACTERISTICS.......2776
SPECIFICATIONS.......2777
POWER FLOW.......2779
FUNCTION AND DESCRIPTION.......2787
TORQUE CONVERTER.......2788
LOCKUP CLUTCH.......2790
PLANETARY GEAR SET.......2792
MULTIPLE-DISC CLUTCH.......2793
FREEWHEEL.......2794
SENSORS AND CONTROLS.......2795
OTHER FUNCTIONS.......2817
TROUBLE CODE AND DIAGNOSIS.......2822
HYDRAULIC SYSTEM.......2831
HYDRAULIC CIRCUIT.......2832
HYDRAULIC CIRCUIT WHEN STARTING ENGINE.......2837
STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE).......2843
REMOVAL AND INSTALLATION (DC 5-SPEED A/T).......2745
DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T).......2846
CLUTCH.......2852
GENERAL DESCRIPTION AND OPERATION.......2853
SPECIFICATIONS.......2854
DIAGNOSTIC INFORMATION AND PROCEDURES.......2855
CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY.......2856
CLUTCH COMPONENTS.......2857