Daewoo Korando 1996-2006 Workshop Service Manual for Repair
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🏷️ 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:...
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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