SsangYong Korando 1996-2006 Full Service Repair Manual
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🏷️ Basic Information Identification Make: SsangYong Model: Korando Generation: First Generation (VJ) and Second Generation (C200 facelift variations relevant to the 2006 cutoff) Years Covered: 1996-2006 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Reputation: Known for its rugged construction and off-road capability, often compared to earlier Jeep models due to its body-on-frame design. Competitive Analysis Competitors 1996-2006: Jeep Cherokee (XJ), Land Rover Discovery, Mitsubishi Pajero (Montero), Toyota 4Runner, Nissan Pathfinder Key Features Manual Utility: Provides step-by-step instructions enabling owners to perform maintenance and repairs efficiently and correctly. Accessibility: Downloadable PDF format allows for instant access and on-the-go reference, crucial for roadside or trailside repairs. Cost Savings: Empowers users to perform their own repairs, saving significant labor costs compared to dealership or independent shop rates. 📋 Manual Details Coverage Areas Primary Focus: Service, Maintenance, Troubleshooting, Repair Intended Audience: DIY Enthusiasts, Professional Mechanics Page Count Estimated Count: Highly comprehensive, estimated 2000+ pages (typical for a full factory service manual) Manual Type Type: Factory Authorized Service and Repair Manual Language Language: English Format Format: PDF Downloadable 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, Engine electrical, Fuel system, Exhaust system, Cooling system, Lubrication system Drivetrain: Transmission (Manual & Automatic), Transfer Case, Drive Shafts, Axles, Differentials Chassis: Suspension (Front & Rear), Steering system, Braking system (ABS included), Wheels and Tires Electrical: Body electrical systems, Lighting, Instrumentation, Audio system, HVAC controls, Powertrain control module (PCM) wiring diagrams, Chassis control module (CCM) wiring diagrams Body: Body construction, Exterior trim, Interior trim, Doors, Windows, Seats, HVAC system components Procedures Included Maintenance: Scheduled maintenance, Fluid changes, Filter replacements, Inspections Troubleshooting: Diagnostic procedures, Symptom-based troubleshooting charts, Fault code explanations Repair: Component removal and installation, Overhaul procedures, Component-specific repair instructions Diagnostics: OBD-II diagnostics, Sensor testing, Actuator testing, ECU diagnostics Technical Depth Depth: Comprehensive: From basic fluid checks and filter changes to complete engine rebuilds, transmission overhauls, and complex electrical system diagnostics. Diagnostic Tools: Information on using scan tools, multimeters, pressure gauges, and specialized diagnostic equipment. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable - allows users to print specific sections or the entire manual. Zoom Functionality Zoom: YES - Allows for detailed examination of diagrams and text. Delivery Method Delivery: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for unzipping downloaded files) Compatibility Operating Systems: Compatible with All Versions of Windows & Mac Content Features Illustrations: High Quality Diagrams, Detailed Exploded Pictures, In-depth Illustrations Text Clarity: Easy to read text sections, Accurate, Clear and Concise text ⚙️ Engine Specifications Primary Engine Offered 1996-2006 Engine Type Petrol: 2.3L (2295cc) 4-cylinder, 2.6L (2597cc) 4-cylinder (older models), 3.2L (3199cc) 6-cylinder Mercedes-Benz M104 (later models) Engine Type Diesel: 2.9L (2874cc) 5-cylinder Mercedes-Benz OM602, 2.3L (2289cc) 4-cylinder turbodiesel (various variants), 2.7L (2696cc) 5-cylinder turbodiesel Mercedes-Benz OM602.9 (later models) Performance Petrol 2.3L Horsepower: Approx. 120-140 HP (depending on specific variant and year) Torque: Approx. 180-190 Nm Performance Diesel 2.9L Horsepower: Approx. 90-109 HP (depending on specific variant and year) Torque: Approx. 190-230 Nm Fuel System Injection Petrol: Multi-point fuel injection (MPI) Injection Diesel: Direct Injection (DI) or Indirect Injection (IDI) with Turbocharging 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission Features Drive System: Part-time 4WD with selectable 2WD/4WD modes and low-range transfer case Fluid Specifications Manual Fluid Type: API GL-4 or GL-5 Gear Oil (SAE 75W-90 or 80W-90 recommended) Fluid Specifications Automatic Fluid Type: Dexron III (or equivalent) 📐 Dimensions Exterior Length Approx Length: 4050 - 4400 mm (varies by body style and generation) Exterior Width Approx Width: 1740 - 1800 mm Exterior Height Approx Height: 1670 - 1750 mm Wheelbase Wheelbase Range: 2400 - 2650 mm Weights Curb Weight: Approx. 1700 - 2000 kg (depending on engine and trim) Gross Vehicle Weight: Approx. 2300 - 2500 kg 🛡️ Safety Features Ratings Crash Test Results: Limited official comprehensive crash test data available for this specific period and region. Earlier models often lacked modern safety features. Active Features Braking System: Front: Ventilated Disc Brakes, Rear: Disc or Drum Brakes (ABS optional on higher trims and later models) Passive Features Restraints: Front airbags (driver and passenger, standard on later models), Seat belts with pre-tensioners. Body Structure: Body-on-frame construction, designed for robustness and off-road durability. 💡 Technology Features Infotainment Audio System: Factory AM/FM/Cassette or CD players, often with basic speaker systems. Aftermarket upgrades are common. Driver Assistance Features: Limited by modern standards. ABS was optional. Cruise control was available on some models. Basic traction control was rare. Connectivity Features: No integrated Bluetooth or smartphone connectivity in factory units. Communication systems were basic or non-existent. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (depending on engine type and driving conditions). Service Intervals Air Filter Interval: Every 15,000 - 30,000 miles (24,000 -...
Comprehensive: From basic fluid checks and filter changes to complete engine rebuilds, transmission overhauls, and complex electrical system diagnostics.
Diagnostic Tools:
Information on using scan tools, multimeters, pressure gauges, and specialized diagnostic equipment.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable - allows users to print specific sections or the entire manual.
Zoom Functionality
Zoom:
YES - Allows for detailed examination of diagrams and text.
Delivery Method
Delivery:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for unzipping downloaded files)
Compatibility
Operating Systems:
Compatible with All Versions of Windows & Mac
Content Features
Illustrations:
High Quality Diagrams, Detailed Exploded Pictures, In-depth Illustrations
Text Clarity:
Easy to read text sections, Accurate, Clear and Concise text
Approx. 120-140 HP (depending on specific variant and year)
Torque:
Approx. 180-190 Nm
Performance Diesel 2.9L
Horsepower:
Approx. 90-109 HP (depending on specific variant and year)
Torque:
Approx. 190-230 Nm
Fuel System
Injection Petrol:
Multi-point fuel injection (MPI)
Injection Diesel:
Direct Injection (DI) or Indirect Injection (IDI) with Turbocharging
🔧 Transmission
Standard Transmission
Type:
5-speed Manual Transmission
Optional Transmission
Type:
4-speed Automatic Transmission
Features
Drive System:
Part-time 4WD with selectable 2WD/4WD modes and low-range transfer case
Fluid Specifications Manual
Fluid Type:
API GL-4 or GL-5 Gear Oil (SAE 75W-90 or 80W-90 recommended)
Fluid Specifications Automatic
Fluid Type:
Dexron III (or equivalent)
📐 Dimensions
Exterior Length
Approx Length:
4050 - 4400 mm (varies by body style and generation)
Exterior Width
Approx Width:
1740 - 1800 mm
Exterior Height
Approx Height:
1670 - 1750 mm
Wheelbase
Wheelbase Range:
2400 - 2650 mm
Weights
Curb Weight:
Approx. 1700 - 2000 kg (depending on engine and trim)
Gross Vehicle Weight:
Approx. 2300 - 2500 kg
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official comprehensive crash test data available for this specific period and region. Earlier models often lacked modern safety features.
Active Features
Braking System:
Front: Ventilated Disc Brakes, Rear: Disc or Drum Brakes (ABS optional on higher trims and later models)
Passive Features
Restraints:
Front airbags (driver and passenger, standard on later models), Seat belts with pre-tensioners.
Body Structure:
Body-on-frame construction, designed for robustness and off-road durability.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD players, often with basic speaker systems. Aftermarket upgrades are common.
Driver Assistance
Features:
Limited by modern standards. ABS was optional. Cruise control was available on some models. Basic traction control was rare.
Connectivity
Features:
No integrated Bluetooth or smartphone connectivity in factory units. Communication systems were basic or non-existent.
🔧 Maintenance
Service Intervals Oil Change
Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (depending on engine type and driving conditions).
Service Intervals Air Filter
Interval:
Every 15,000 - 30,000 miles (24,000 - 48,000 km), or more frequently in dusty conditions.
Service Intervals Transmission Fluid
Interval:
Manual: Inspect annually, change every 30,000 - 60,000 miles (48,000 - 96,000 km). Automatic: Change every 30,000 - 50,000 miles (48,000 - 80,000 km).
Fluid Specifications Engine Oil
Oil Type Petrol:
API SG, SH, SJ or equivalent; Viscosity: 10W-30 or 10W-40 (check owner's manual for specific climate recommendations).
Oil Type Diesel:
API CG-4 or CH-4; Viscosity: 10W-30 or 15W-40 (check owner's manual).
Fluid Specifications Coolant
Coolant Type:
Ethylene Glycol based coolant with corrosion inhibitors (e.g., Hyundai/Kia Long Life Coolant or equivalent).
Known Issues
Common Problems:
Corrosion on chassis and body, aging rubber bushings and suspension components, potential for overheating in older diesel engines, electrical gremlins due to wiring age, clutch wear (manual transmissions).
Transfer case linkage wear, hub actuator issues (vacuum or electric depending on year).
📚 Vehicle History
Brand Heritage
Origin:
SsangYong Motor Company, South Korea. Known for producing robust, often rugged vehicles, with significant technological contributions from partnerships (e.g., Mercedes-Benz).
Model Evolution
First Generation Vj:
Launched in 1992, heavily influenced by the design of the first-generation Jeep Cherokee (XJ) and utilizing some Jeep technology under license. Known for its traditional SUV characteristics.
Second Generation Facelift Relevant To 2006:
While the C200 Korando (New Korando) was introduced later, the 1996-2006 period primarily covers the VJ generation and its variations. The manual is crucial for understanding the evolution of engines and features within this long-running generation.
Production
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Off Road Capability:
Praised for its robust chassis and off-road prowess, particularly by off-road enthusiasts. Often seen as a capable budget alternative to more established 4x4s.
Value Proposition:
Considered a strong value proposition for a capable SUV, especially for those prioritizing off-road performance and utility over luxury or advanced technology.