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Daewoo Korando 1996-2006 Workshop Service Manual for Repair

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The Korando, specifically the First Generation (C200) model, is a compact SUV known for its robust, body-on-frame construction and significant off-road capability, often compared to contemporaries like the Jeep Cherokee and Mitsubishi Pajero. Originally drawing design cues from early Jeep models, the Korando offered a range of diesel and gasoline engines, typically paired with a 5-speed manual or optional automatic transmission and a part-time 4WD system. Available in various body styles including 2-door convertible and 4-door wagon, this vehicle was engineered for durability and utility, making it a capable choice for both on-road driving and more challenging terrain. This comprehensive workshop service manual provides essential information for the maintenance and repair of Korando vehicles produced between 1996 and 2006. Covering a vast array of systems, including detailed engine diagnostics, transmission service, drivetrain and suspension repairs, brake systems, steering, and the complete electrical system, this manual is an invaluable resource. It includes step-by-step repair instructions, disassembly and assembly procedures, adjustment guidelines, crucial technical specifications, and troubleshooting advice, all supported by diagrams and photos. The manual is designed to assist owners, mechanics, and technicians in effectively maintaining and restoring the vehicle to optimal working condition. 🏷️ Basic Information Identification Make: Daewoo Model: Korando Generation: First Generation (C200) Codes Model Code: C200 (Approximate, varies by specific market and sub-model) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Competitive Analysis Competitors: Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, Suzuki Vitara/Grand Vitara, Ford Explorer (early generations). Key Features Off Road Capability: Body-on-frame construction and available 4WD systems provided significant off-road capability for its class. Design Origin: Originally based on the SsangYong Korando, which itself had roots in early Jeep designs (CJ-series). 📋 Manual Details Coverage Areas Applicable Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Total Pages: 1462 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed coverage for various engine options (e.g., diesel, gasoline variants common in this era). Transmission: Manual and Automatic transmission service, repair, and diagnostics. Drivetrain: 4WD system operation, service, and repair for transfer case and axles. Suspension: Front and rear suspension systems, including components, alignment, and repair procedures. Brakes: Brake system service, including hydraulic components, ABS (if equipped), and disc/drum brake servicing. Steering: Power steering system diagnosis and repair, steering column and linkage service. Electrical: Complete electrical system coverage, including wiring diagrams, lighting, ignition, charging, starting, and accessories. Bodywork: Body panel repair, structural components, doors, glass, and interior trim removal/installation. HVAC: Heating, Ventilation, and Air Conditioning system service and repair. Fuel System: Fuel injection systems, fuel pumps, lines, and filters for gasoline and diesel engines. Cooling System: Radiator, thermostat, water pump, and fan service. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipe replacement. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and general upkeep. Troubleshooting: Diagnostic procedures for common problems, fault code interpretation (if applicable), and symptom-based troubleshooting. Repair: Detailed, step-by-step repair instructions for all major vehicle systems. Disassembly Assembly: Comprehensive instructions for removing and reinstalling components. Adjustments: Procedures for adjusting various systems, such as brakes, clutch, and engine timing. Specifications: Key service data, including torque values, tolerances, and fluid capacities. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to detailed component overhauls and diagnostics. Illustrations: Includes detailed diagrams, exploded views, and photos to guide repairs. Special Tools: References and illustrations for required special service tools. 📊 Manual Specifications File Format Quality: Printable PDF, allowing for high-quality printing of any page. Searchability: Likely text-searchable PDF, facilitating quick information retrieval. Print Quality Print Capability: Yes, all pages are printable. Binding Type Binding Description: Digital PDF, no physical binding. Paper Type Paper Description: N/A (Digital Format) Compatibility Operating Systems: Windows, Mac, Linux OS compatible via Adobe Reader or similar PDF viewer. Requirement Software: Adobe Reader or compatible PDF viewer. ⚙️ Engine Specifications Primary Engine Engine Types: Primarily known for its diesel engines (e.g., 2.3L, 2.9L Mercedes-Benz derived diesel) and various gasoline engines (e.g., 2.0L, 2.2L, 3.2L inline-4 and inline-6, and V6 options). Performance Horsepower Range: Typically ranging from 70-120 HP for diesel variants and 100-170 HP for gasoline variants, depending on specific engine and tuning. Torque Range: Diesel engines offered good low-end torque for off-road use. Fuel System Fuel Delivery: Typically indirect injection (diesel) or multi-point fuel injection (gasoline). 🔧 Transmission Standard Type: Often equipped with a 5-speed manual transmission. Optional Type: Automatic transmission was also available. Features Drivetrain Options: Part-time 4WD system with a manually selectable transfer case. 📐 Dimensions Exterior Body Styles: Typically available as a 2-door convertible, 4-door wagon, and sometimes a pickup variant. Weights Curb Weight: Varies significantly by configuration, but generally in the range of 3,500 - 4,500 lbs. 🛡️ Safety Features Ratings Crash Test Data: Limited comprehensive crash test data...
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Daewoo Korando 1996-2006 Workshop Service Manual for RepairDaewoo Korando 1996-2006 Workshop Service Manual for RepairDaewoo Korando 1996-2006 Workshop Service Manual for RepairDaewoo Korando 1996-2006 Workshop Service Manual for Repair
The Korando, specifically the First Generation (C200) model, is a compact SUV known for its robust, body-on-frame construction and significant off-road capability, often compared to contemporaries like the Jeep Cherokee and Mitsubishi Pajero. Originally drawing design cues from early Jeep models, the Korando offered a range of diesel and gasoline engines, typically paired with a 5-speed manual or optional automatic transmission and a part-time 4WD system. Available in various body styles including 2-door convertible and 4-door wagon, this vehicle was engineered for durability and utility, making it a capable choice for both on-road driving and more challenging terrain. This comprehensive workshop service manual provides essential information for the maintenance and repair of Korando vehicles produced between 1996 and 2006. Covering a vast array of systems, including detailed engine diagnostics, transmission service, drivetrain and suspension repairs, brake systems, steering, and the complete electrical system, this manual is an invaluable resource. It includes step-by-step repair instructions, disassembly and assembly procedures, adjustment guidelines, crucial technical specifications, and troubleshooting advice, all supported by diagrams and photos. The manual is designed to assist owners, mechanics, and technicians in effectively maintaining and restoring the vehicle to optimal working condition.
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Korando
Generation:
First Generation (C200)
Codes
Model Code:
C200 (Approximate, varies by specific market and sub-model)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-Road Vehicle
Competitive Analysis
Competitors:
Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, Suzuki Vitara/Grand Vitara, Ford Explorer (early generations).
Key Features
Off Road Capability:
Body-on-frame construction and available 4WD systems provided significant off-road capability for its class.
Design Origin:
Originally based on the SsangYong Korando, which itself had roots in early Jeep designs (CJ-series).
📋 Manual Details
Coverage Areas
Applicable Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Page Count
Total Pages:
1462
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage for various engine options (e.g., diesel, gasoline variants common in this era).
Transmission:
Manual and Automatic transmission service, repair, and diagnostics.
Drivetrain:
4WD system operation, service, and repair for transfer case and axles.
Suspension:
Front and rear suspension systems, including components, alignment, and repair procedures.
Brakes:
Brake system service, including hydraulic components, ABS (if equipped), and disc/drum brake servicing.
Steering:
Power steering system diagnosis and repair, steering column and linkage service.
Electrical:
Complete electrical system coverage, including wiring diagrams, lighting, ignition, charging, starting, and accessories.
Bodywork:
Body panel repair, structural components, doors, glass, and interior trim removal/installation.
HVAC:
Heating, Ventilation, and Air Conditioning system service and repair.
Fuel System:
Fuel injection systems, fuel pumps, lines, and filters for gasoline and diesel engines.
Cooling System:
Radiator, thermostat, water pump, and fan service.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and pipe replacement.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, and general upkeep.
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation (if applicable), and symptom-based troubleshooting.
Repair:
Detailed, step-by-step repair instructions for all major vehicle systems.
Disassembly Assembly:
Comprehensive instructions for removing and reinstalling components.
Adjustments:
Procedures for adjusting various systems, such as brakes, clutch, and engine timing.
Specifications:
Key service data, including torque values, tolerances, and fluid capacities.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to detailed component overhauls and diagnostics.
Illustrations:
Includes detailed diagrams, exploded views, and photos to guide repairs.
Special Tools:
References and illustrations for required special service tools.
📊 Manual Specifications
File Format
Quality:
Printable PDF, allowing for high-quality printing of any page.
Searchability:
Likely text-searchable PDF, facilitating quick information retrieval.
Print Quality
Print Capability:
Yes, all pages are printable.
Binding Type
Binding Description:
Digital PDF, no physical binding.
Paper Type
Paper Description:
N/A (Digital Format)
Compatibility
Operating Systems:
Windows, Mac, Linux OS compatible via Adobe Reader or similar PDF viewer.
Requirement
Software:
Adobe Reader or compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Types:
Primarily known for its diesel engines (e.g., 2.3L, 2.9L Mercedes-Benz derived diesel) and various gasoline engines (e.g., 2.0L, 2.2L, 3.2L inline-4 and inline-6, and V6 options).
Performance
Horsepower Range:
Typically ranging from 70-120 HP for diesel variants and 100-170 HP for gasoline variants, depending on specific engine and tuning.
Torque Range:
Diesel engines offered good low-end torque for off-road use.
Fuel System
Fuel Delivery:
Typically indirect injection (diesel) or multi-point fuel injection (gasoline).
🔧 Transmission
Standard
Type:
Often equipped with a 5-speed manual transmission.
Optional
Type:
Automatic transmission was also available.
Features
Drivetrain Options:
Part-time 4WD system with a manually selectable transfer case.
📐 Dimensions
Exterior
Body Styles:
Typically available as a 2-door convertible, 4-door wagon, and sometimes a pickup variant.
Weights
Curb Weight:
Varies significantly by configuration, but generally in the range of 3,500 - 4,500 lbs.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited comprehensive crash test data readily available for specific model years and regions; generally considered basic for its era.
Active Features
ABS:
Optional on some models, particularly later ones.
Passive Features
Airbags:
Driver and passenger airbags were optional or standard depending on trim and year.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD or cassette player; options for upgraded sound systems were available.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Phone Integration:
N/A for this era; aftermarket solutions would be required.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions and specific engine.
Timing Belt:
Crucial for specific engines; interval varies significantly (e.g., 60,000-100,000 miles / 100,000-160,000 km). Consult manual for exact specifications.
Fluid Specifications
Engine Oil:
API SG/SH or higher, viscosity typically 5W-30, 10W-30, or 10W-40 depending on ambient temperature and engine type (diesel/gasoline). Specific diesel oils often recommended.
Coolant:
Ethylene glycol based coolant (e.g., Dex-Cool compatible or similar) with a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (e.g., SAE 75W-90 or 80W-90).
Transmission Fluid Automatic:
Dexron III or equivalent ATF.
Known Issues
Diesel Engines:
Glow plug issues, injector pump problems, potential for head gasket leaks on higher mileage units.
Rust:
Prone to rust, especially in wheel arches, rocker panels, and chassis components, common for vehicles of this era and construction type.
Electrical Gremlins:
Wiring harness issues, corrosion in connectors, and sensor failures can lead to intermittent electrical problems.
Suspension Wear:
Bushings, ball joints, and tie rod ends can wear out due to age and typical off-road use.
📚 Vehicle History
Brand Heritage
Daewoo Automotive:
Daewoo Motor Company was a South Korean manufacturer known for producing a range of vehicles, often in partnership or using licensed technology from other manufacturers.
Model Evolution
Korando Lineage:
The Korando nameplate has a long history in South Korea, with this generation representing a significant update and period of Daewoo ownership.
Production
Manufacturing Locations:
Primarily South Korea, with potential assembly in other markets.
🏆 Awards & Recognition
Recognitions
Off Road Prowess:
While not typically winning awards, the Korando was recognized for its sturdy, go-anywhere capability relative to its price point.
Ratings
Reliability Perception:
Mixed perception; robust mechanicals could be reliable if well-maintained, but build quality and electricals could be inconsistent.
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