CONTENTS: 2018 SsangYong Rexton (Y402) Repair Manual

• GENERAL
• D22DTR ENGINE
• G20GDI ENGINE
• ELECTRICAL SYSTEM
• CHASSIS
• BODY
• ELECTRICAL WIRING DIAGRAM LHD
• ELECTRICAL WIRING DIAGRAM RHD

SAMPLE PAGES

2018 SsangYong Rexton (Y402) – Comprehensive Buyer Guide

Overview

The 2018 SsangYong Rexton (Y402) is a full-size SUV and the fourth generation of SsangYong’s flagship model. Launched in 2017, it represents a significant upgrade over its predecessor with modern styling, improved build quality, and advanced features.

Market Position: Body-on-frame SUV competing in the large SUV segment, offering 7-seat capability and strong towing capacity at a competitive price point.

Design: Contemporary design by former Bentley designer, featuring a bold front grille, clean lines, and a more premium appearance than previous generations.

Target Audience: Families needing space, towing enthusiasts, and budget-conscious buyers seeking a large SUV alternative to mainstream brands.

Technical Specifications

Engine Options:

• 2.2L e-XDi220 diesel engine (primary market)
  • Power: 181 hp (135 kW) @ 4,000 rpm
  • Torque: 420 Nm (310 lb-ft) @ 1,400-2,800 rpm
• 2.0L G20D gasoline engine (select markets)
  • Power: 224 hp @ 6,000 rpm
  • Torque: 350 Nm @ 1,400-4,000 rpm

Transmission:

• 7-speed automatic transmission (Mercedes-Benz sourced)

Drivetrain:

• 4WD system with electronic transfer case
• Selectable drive modes: 2H, 4H, 4L
• Electronic locking rear differential (on some trims)

Dimensions:

• Length: 4,850 mm (190.9 in)
• Width: 1,960 mm (77.2 in)
• Height: 1,825 mm (71.9 in)
• Wheelbase: 2,865 mm (112.8 in)
• Ground clearance: 210 mm (8.3 in)

Weights & Capacities:

• Curb weight: 2,120-2,230 kg (4,674-4,916 lbs)
• Towing capacity: 3,500 kg (7,716 lbs) braked
• Payload: ~700 kg
• Fuel tank: 80 liters (21.1 gallons)

Performance:

• 0-100 km/h: ~11.5 seconds (diesel)
• Top speed: ~180 km/h (112 mph)
• Fuel economy: 7.5-9.5 L/100km (25-31 mpg) combined

Chassis & Suspension:

• Body-on-frame construction
• Front: Independent double wishbone
• Rear: 5-link coil spring
• Disc brakes all around (ventilated front)

Seating & Cargo:

• 5 or 7-seat configurations
• Cargo capacity: 820-1,977 liters (29-70 cu ft)

Safety Features:

• 6-9 airbags depending on market
• ABS with EBD
• Electronic Stability Program (ESP)
• Hill Start Assist & Hill Descent Control
• Autonomous Emergency Braking (AEB)
• Lane Departure Warning
• Blind Spot Detection
• Rear Cross Traffic Alert

Top 10 Mechanical & Electrical Issues

1. EGR Valve & Cooler Failures

• • Symptoms: Engine warning light, loss of power (limp mode), rough idle, black smoke from exhaust, poor fuel economy
  • Root Cause: Carbon buildup in EGR valve and cooler, particularly in diesel engines with short urban trips; poor quality diesel fuel
  • Fix: Clean or replace EGR valve and cooler assembly; perform DPF regeneration
  • Cost: $300-$800 (cleaning) / $800-$1,500 (replacement)

2. Diesel Particulate Filter (DPF) Blockage

• • Symptoms: Warning light, reduced power, increased fuel consumption, engine won’t rev beyond 3,000 rpm, rough running
  • Root Cause: Insufficient highway driving for passive regeneration; failed active regeneration cycles; sensor failures
  • Fix: Forced regeneration with diagnostic tool; DPF cleaning or replacement; drive cycle modification
  • Cost:$150-$300 (forced regen) / $1,200-$2,500 (DPF replacement)

3. Transfer Case Actuator Failure

• • Symptoms: 4WD warning light, inability to engage/disengage 4WD, grinding noises when attempting to shift modes, stuck in 2WD or 4WD
  • Root Cause: Faulty electronic actuator motor, corroded connections, software glitches
  • Fix:Replace transfer case actuator motor; update control module software; check and clean electrical connections
  • Cost:$400-$900

4. Turbocharger Issues

• • Symptoms: Loss of power, excessive smoke (blue or black), whistling or whining noise, oil leaks around turbo, check engine light
  • Root Cause: Oil starvation, contaminated oil, carbon buildup, worn bearings, boost leak
  • Fix: Replace turbocharger; check and repair oil feed/return lines; replace intercooler hoses if split
  • Cost: $1,200-$2,800

5. Injector Problems (Diesel)

• • Symptoms: Hard starting, misfiring, rough idle, knocking noise, black smoke, increased fuel consumption, engine warning light
  • Root Cause: Poor fuel quality, carbon deposits, worn injector seals, electrical faults in injector circuitry
  • Fix: Replace faulty injectors; clean fuel system; reprogram ECU for injector coding
  • Cost: $300-$600 per injector / $1,500-$3,000 for full set

6. Transmission Jerking/Slipping

• • Symptoms: Harsh shifts, delayed engagement, jerking during gear changes (especially 2nd-3rd), shuddering at low speeds
  • Root Cause: Transmission fluid degradation, software calibration issues, torque converter problems, valve body wear
  • Fix: Transmission fluid and filter change; software update; valve body replacement in severe cases
  • Cost: $200-$400 (service) / $800-$2,000 (valve body) / $3,000-$5,000 (rebuild)

7. Electronic Parking Brake Faults

• • Symptoms: EPB warning light, parking brake won’t release/engage, grinding noise from rear wheels, brake drag
  • Root Cause: Faulty actuator motors, corroded cables, software issues, worn brake pads triggering sensor errors
  • Fix: Replace EPB actuators; calibrate system with diagnostic tool; replace rear brake pads and perform reset
  • Cost: $400-$800 per side

8. Alternator Failure

• • Symptoms: Battery warning light, dimming lights, electrical system malfunctions, dead battery, whining noise from engine bay
  • Root Cause: Bearing wear, voltage regulator failure, diode failure, water ingress in some cases
  • Fix:Replace alternator; check battery and charging system; inspect serpentine belt
  • Cost: $400-$700

9. Air Conditioning Compressor Failure

• • Symptoms: No cold air, intermittent cooling, loud clicking or grinding noise, refrigerant leak, AC clutch not engaging
  • Root Cause: Clutch bearing failure, compressor seal leaks, electrical faults, refrigerant contamination
  • Fix: Replace AC compressor; evacuate and recharge system; replace receiver-drier
  • Cost: $600-$1,200

10. Front Suspension Bushings Wear

• • Symptoms: Clunking noise over bumps, wandering steering, uneven tire wear, vibration through steering wheel
  • Root Cause: Normal wear and tear, especially on rough roads; poor quality rubber compounds
  • Fix: Replace control arm bushings; perform wheel alignment; inspect ball joints
  • Cost: $300-$600

Top 5 Competitors

1. Toyota Fortuner

• Strengths: Legendary reliability, strong resale value, excellent off-road capability, proven 2.8L diesel engine
• Weaknesses: Higher price, less modern interior, firmer ride
• Price Comparison: 15-25% more expensive than Rexton

2. Mitsubishi Pajero Sport

• Strengths: Superior off-road credentials, Super Select 4WD system, good build quality, 7-seat configuration
• Weaknesses: Older platform, less refined on-road, smaller cargo space
• Price Comparison: Similar pricing to Rexton

3. Isuzu MU-X

• Strengths: Excellent diesel engine reliability, competitive pricing, good towing capacity, spacious interior
• Weaknesses: Basic interior materials, less tech features, truck-like ride
• Price Comparison: Comparable to Rexton

4. Ford Everest

• Strengths: Powerful engine options, refined road manners, modern tech, good safety ratings
• Weaknesses: Higher running costs, potential turbo issues, expensive parts
• Price Comparison: 10-20% more expensive

5. Hyundai Santa Fe (7-seater)

• Strengths: Better on-road dynamics, modern interior, comprehensive warranty, fuel-efficient engines
• Weaknesses: Less towing capacity, car-based platform (not body-on-frame), lower ground clearance
• Price Comparison: Similar to slightly higher pricing

Top 10 Recalls, Advisories & TSB Highlights

Note: Recall availability varies by market. The following are notable issues reported globally:

1. Fuel Pump Relay Recall

• Issue: Defective fuel pump relay could cause engine stalling
• Markets: Various
• Fix: Replace fuel pump relay

2. Seatbelt Pretensioner Advisory

• Issue: Potential seatbelt pretensioner malfunction in frontal collisions
• Markets: Select European markets
• Fix: Inspection and replacement if necessary

3. Brake Booster Vacuum Hose TSB

• Issue: Vacuum hose may crack causing reduced brake assist
• Fix: Replace with improved hose design

4. DPF Software Update

• Issue: DPF regeneration occurring too frequently or failing
• Fix: ECU software update to optimize regeneration cycles

5. Transmission Software Calibration TSB

• Issue: Harsh shifting, especially during cold starts
• Fix: Transmission control module software update

6. Rear Differential Noise TSB

• Issue: Whining or humming noise from rear differential
• Fix: Replace differential fluid with updated specification

7. Infotainment System Freezing

• Issue: Touchscreen becomes unresponsive or freezes
• Fix: Software update for head unit

8. Sunroof Drainage Advisory

• Issue: Sunroof drains may become blocked causing water leaks
• Fix: Regular cleaning of drain tubes; improved design on later models

9. Headlight Condensation TSB

• Issue: Moisture buildup inside headlight assemblies
• Fix: Improved vent design; replacement under warranty

10. Auxiliary Battery Drain

• Issue: Auxiliary battery (if equipped) draining when vehicle parked
• Fix: Software update to power management system

Maintenance Schedule

Every 10,000 km (6,000 miles) or 6 months:

• Engine oil and filter change (diesel)
• Visual inspection of brakes, suspension, exhaust
• Check all fluid levels
• Tire rotation and pressure check

Every 20,000 km (12,000 miles) or 12 months:

• Engine oil and filter (gasoline)
• Cabin air filter replacement
• Brake fluid check
• Coolant level inspection
• Battery test

Every 30,000 km (18,000 miles):

• Air filter replacement
• Fuel filter replacement (diesel)
• Inspect drive belts
• Check 4WD system operation

Every 40,000 km (24,000 miles) or 2 years:

• Brake fluid replacement
• Transmission fluid inspection
• Inspect steering and suspension components
• DPF inspection (diesel)

Every 60,000 km (36,000 miles):

• Spark plugs (gasoline)
• Transmission fluid and filter change
• Transfer case fluid change
• Differential fluid change (front and rear)
• Coolant replacement
• Drive belt replacement

Every 80,000 km (48,000 miles):

• Major service interval
• Replace all filters
• Inspect turbocharger (diesel)
• Check EGR system

Every 100,000 km (60,000 miles):

• Timing chain inspection (though typically good for life)
• Comprehensive brake system overhaul
• Suspension component replacement as needed

Special Maintenance Notes:

• DPF regeneration should occur automatically; monitor warning lights
• If primarily used for short trips, perform monthly highway run (20+ minutes)
• Transfer case should be engaged monthly to maintain lubrication
• Use manufacturer-specified diesel fuel with adequate cetane rating

10 FAQs for Buyers

1. Is the SsangYong Rexton reliable?

Generally reliable for a budget SUV, but not at Toyota/Lexus levels. The 2018+ Y402 generation is significantly improved over previous models. Expect some minor electrical issues and typical diesel maintenance. Reliability heavily depends on regular servicing and proper diesel maintenance (DPF care).

2. What’s the real-world fuel economy?

Diesel: 9-11 L/100km (21-26 mpg) in mixed driving; 7-8 L/100km (29-33 mpg) highway; 12-14 L/100km (17-20 mpg) in heavy city traffic or when towing. Gasoline: 11-13 L/100km (18-21 mpg) combined. 4WD models consume slightly more.

3. How does the 7-year warranty work?

SsangYong typically offers a 7-year/150,000 km warranty (varies by market). This is transferable to subsequent owners. However, warranty support quality varies by country and dealer network strength. Always verify local warranty terms before purchase.

4. Can it really tow 3,500 kg?

Yes, when properly equipped with tow package and braked trailer. The diesel engine provides good torque for towing. However, ensure you have transmission cooler, and avoid constant heavy towing in hot climates without adequate cooling modifications.

5. How does it compare to a Toyota Fortuner?

The Rexton offers more space, features, and value for money. The Fortuner has better reliability, resale value, and dealer network. Choose Rexton if budget-conscious and want features; choose Fortuner if prioritizing long-term reliability and resale.

6. Are parts expensive and hard to find?

Parts availability varies significantly by market. In markets with established SsangYong presence (Korea, Australia, UK, Middle East), parts are reasonably available and affordable. In other markets, expect longer wait times and potentially higher costs. Many mechanical components share lineage with Mercedes, offering some cross-compatibility.

7. Is the diesel engine problematic?

The 2.2L diesel is generally solid but requires proper maintenance. Common issues include DPF blockage (if used for short trips), EGR carbon buildup, and occasional injector problems. Use quality diesel fuel, perform regular oil changes, and ensure adequate highway driving for DPF health.

8. What about off-road capability?

Quite capable with 210mm ground clearance, 4L low range, and locking rear differential. Approach/departure angles are reasonable (24°/25°). Not as capable as Land Cruiser or Pajero in extreme conditions, but handles moderate off-road situations well. Body-on-frame construction adds durability.

9. Should I buy new or used?

Used examples offer excellent value depreciation. Check service history meticulously, especially DPF and EGR maintenance. 2019-2020 models received minor improvements and updates. Buying certified pre-owned through official dealers provides some warranty protection.

10. What are the running costs?

Annual running costs (excluding fuel): $1,500-$2,500 including insurance, registration, and scheduled maintenance. Diesel models generally have higher maintenance costs due to DPF, EGR servicing. Budget for potential DPF replacement ($1,500-$2,500) around 100,000-150,000 km if used primarily in city driving.

Final Buyer Recommendations

✅ Buy If:

• You need 7-seat capacity and strong towing capability on a budget
• Value for money and features are priorities over brand prestige
• You have access to a competent SsangYong dealer network
• Primarily highway/rural driving (diesel DPF health)
• You’re comfortable with a less mainstream brand
• You want body-on-frame durability for occasional off-road use
• The 7-year warranty provides peace of mind in your market

❌ Avoid If:

• You prioritize maximum reliability and resale value (buy Toyota instead)
• Dealer network is weak or non-existent in your area
• You primarily do short urban trips (diesel DPF issues)
• You need best-in-class refinement and on-road dynamics
• You’re concerned about brand perception and resale
• You require extensive aftermarket support and accessories

📋 Pre-Purchase Checklist:

1. Service History: Verify all scheduled maintenance, especially DPF and EGR servicing
2. DPF Status: Have dealer check DPF soot loading and regeneration history
3. Test Drive: Test 4WD engagement (all modes: 2H, 4H, 4L), transmission shifts, and EPB operation
4. Inspection Points: Check for oil leaks (turbo, injectors), listen for turbo whistle, inspect for smoke
5. Warranty: Confirm remaining warranty coverage and transferability
6. Software: Ensure all TSB updates have been applied
7. Dealer Support: Verify local dealer capability and parts availability

Value Proposition

The 2018 SsangYong Rexton offers exceptional value in the large SUV segment. You get 7 seats, 3,500 kg towing, body-on-frame construction, and generous equipment for 25-40% less than mainstream Japanese competitors. However, this comes with trade-offs in brand reputation, resale value, and potential reliability concerns.

Best For: Pragmatic buyers who need genuine SUV capability without premium pricing, and who plan to keep the vehicle long-term (making resale less relevant).

Rating: 7.5/10 for value-conscious buyers | 6/10 for reliability-focused buyers

Bottom Line: A capable, spacious, and well-equipped SUV that punches above its weight on value. Success depends on proper diesel maintenance and having adequate dealer support in your region. Not the most reliable choice, but arguably the most SUV your money can buy.