Description

Ssangyong Rexton Service Manual

You have a Ssangyong Rexton Service Manual on the bench in front of you. That means you finally have the same binder the dealer techs used when these trucks were new. 587 pages of actual factory documentation – not some aftermarket rewrite where they guess at the coolant flow direction. I’ve pulled enough corner-cut repairs off wrecked Rextons to know the difference. This is the real deal from SSANGYONG MOTOR CO., LTD., PYUNGTAEK, KOREA. Volume 1 of 2, covering the DI engine, and it lands in your hands as a clean PDF from AutoRepairManuals.

Ssangyong Rexton Service Manual: What’s Inside the Engine Sections

Open the TOC and you see ENGINE ASSEMBLY DI01, ENGINE HOUSING DI02, INTAKE SYSTEM DI03, EXHAUST SYSTEM DI04, LUBRICATION SYSTEM DI05, COOLING SYSTEM DI06, FUEL SYSTEM DI07, ENGINE CONTROL SYSTEM DI08, ELECTRIC DEVICES AND SENSORS DI09, and DIAGNOSIS DI10. That covers every system that makes the Rexton DI engine run. The GENERAL INFORMATION section DI0A includes the coolant flow chart (page DI0A-20) and the fuel supply system diagram (page DI0A-22). If you’re swapping an engine or chasing a hard start, those two pages alone save you the kind of time that pays for the manual three times over.

Cooling System and Fuel System: Two Systems You Can’t Afford to Guess On

You need the exact torque for the cylinder head bolts? Section DI0A has a table labeled “Tightening torque of standard bolts” – page DI0A-37. Don’t trust a third-party web forum. Cooling system specs are laid out in DI06 with the coolant flow chart. Fuel system DI07 covers the supply system and injector removal sequence. I’ve seen a mis-torqued injector clamp cause a fuel leak that wiped out a customer’s weekend. This manual stops that.

Does This Manual Include Torque Specs?

Yes. The general information section gives the tightening torque of standard bolts. Each system section – engine assembly, intake, exhaust – repeats the specific torque values for that component. For example, the engine housing section DI02 tells you the fasteners for the main bearing caps. Every spec is in imperial units as published by the factory. No conversions to guess.

7 Systems Covered in the TOC

Engine, housing, intake, exhaust, lubrication, cooling, fuel – seven major systems plus the control system, electric devices, and a full diagnosis chapter. That diagnosis section DI10 is what separates this from a basic repair manual. It gives fault codes, sensor test procedures, and a step‑by‑step diagnostic path. If the ECM is throwing a code for the pre‑heating system, you go to DI0A‑13 for the electrical components and start testing. No fluff, no rewrites.

Get the Right Data for Sensors and Diagnosis

Section DI09 covers electric devices and sensors: crankshaft position, camshaft position, knock sensors, the whole lineup. The diagnosis chapter DI10 walks you through each code. I’ve used this manual to trace a no‑start on a Rexton with a bad ECU ground that every aftermarket guide missed. That’s the difference between OEM data and a reprint.

Source Authenticity: Why This Beats Aftermarket Copies

This is the official SSANGYONG MOTOR CO. service manual. The OCR excerpt shows the foreword: “This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.” It also states “All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval.” Aftermarket shops re‑type tables and lose torque values. This doesn’t. You get the factory flow charts, the lifting points (page DI0A‑36), and the safety guidelines. No shortcuts.

FAQ

Does this manual cover the 2.9L diesel engine?

Yes. The DI engine sections cover the 2.9L four‑cylinder diesel used in the Rexton.

Can I use this for a 2006 Rexton with the 2.7L?

The manual is for the DI engine family. Check the vehicle identification section DI0A‑28 to see if your VIN range matches. If your truck has the D27DT, some intake and control specs differ. The manual lists maintenance intervals on page DI0A‑26 that apply across most DI variants.

Are wiring diagrams included?

Wiring is covered in the ENGINE CONTROL SYSTEM DI08 and ELECTRIC DEVICES AND SENSORS DI09. The sensor connector views and pinouts are there. Full harness routing is not in volume 1; that is in volume 2.

How do I access after purchase?

Instant PDF format. No waiting for a disc.

You need this manual if you’re touching a Rexton DI engine. The aftermarket stuff will get you close, but close leaks oil and sends transmissions to the recycler. Access the Factory Manual from AutoRepairManuals today. Pair it with the related SsangYong Labor Time Guide to quote jobs accurately, and check the 2002 SsangYong BTRA M74 4WD Auto Transmission Manual if you’re also swapping the transmission. For steering work, the Ssangyong Labor Time Guide For Services – Section: Steering gives you shop rate data. For broader context on diesel engine standards, see the Automotive Industry Overview and Manual Transmission articles. Stop guessing. Use OEM data.