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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 -...
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SsangYong Korando 1996-2006 Full Service Repair Manual
🏷️ 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 - 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).
Diesel Specific:
Glow plug issues, injector pump wear, turbocharger seals.
4Wd System:
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.
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