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Ssangyong Korando 1996-2006 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: SsangYong Model: Korando Generation Model Years Covered: 1996-2006 Codes Chassis Codes: KGC100, KGL100 (based on likely generation for this year range) 👋 Introduction Market Position Segment: Compact SUV / Off-road Utility Vehicle Competitive Analysis Competitors: Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, Land Rover Defender (to some extent), Daewoo Korando (earlier models). Key Features Design Philosophy: Rugged body-on-frame construction, capable off-road performance, often available with 4WD. Target Audience: Enthusiasts seeking an affordable, capable off-road vehicle, utility-focused buyers. 📋 Manual Details Coverage Areas Vehicle Coverage: SsangYong Korando 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Total Pages: 2053 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine block, cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, timing systems, lubrication system, cooling system, intake and exhaust manifolds. Engine Management: Fuel injection system (EFI), ignition system, emissions control systems, sensors, actuators, ECU diagnostics. Transmission Manual: Gearbox assembly, clutch, shift mechanisms, transfer case operation (if applicable). Transmission Automatic: Automatic transmission assembly, torque converter, valve body, transmission control unit (TCU), fluid lines. Drivetrain: Front axle, rear axle, driveshafts, differentials, universal joints, constant velocity (CV) joints. Suspension: Front suspension (e.g., independent, solid axle), rear suspension (e.g., leaf springs, multi-link), shock absorbers, springs, control arms, stabilizers. Steering: Steering gearbox/rack and pinion, power steering system (pump, fluid, lines), steering column, tie rods, steering knuckles. Brakes: Front and rear brake systems (disc/drum), master cylinder, brake booster, hydraulic lines, brake calipers, wheel cylinders, parking brake system, ABS (if equipped). Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, body control modules. Body And Chassis: Body panels, chassis frame, doors, hood, tailgate, interior trim, body sealing, structural components. HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant circuits, controls. Diagnostics: On-board diagnostics (OBD) information, diagnostic trouble codes (DTCs), diagnostic procedures. Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, lubrication. Troubleshooting: System-by-system diagnostic flowcharts, common problems and solutions, symptom-based troubleshooting. Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly. Installation: Procedures for installing new or replacement parts and components. Adjustment: Procedures for adjusting various systems, such as brakes, clutch, timing, and emissions. Disassembly Assembly: Detailed breakdown and reassembly of major vehicle systems and components. Wiring Diagrams: Comprehensive electrical wiring schematics for various vehicle systems. Special Tool Usage: Identification and application of specialized service tools required for specific procedures. Technical Depth Depth: Comprehensive 'bumper-to-bumper' coverage suitable for professional mechanics and experienced DIY enthusiasts. Detail Level: Includes detailed step-by-step instructions, explanations, pictorial diagrams, exploded views, and photos. Specifications Data: Provides service data, specifications lists, tightening torques, checking and adjusting parameters, and allowable limits. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (typically, depending on PDF creation) Print Quality Printability: Yes, all pages are printable. Resolution: High resolution, suitable for clear printing. Binding Type Binding: Digital (Instant Download - PDF) Paper Type Paper: N/A (Digital Format) Compatibility Operating Systems: Windows, Mac, Linux OS Software Requirement: Adobe Reader or compatible PDF viewer. ⚙️ Engine Specifications Primary Engine Engine Type Common: Likely inline-4 cylinder diesel (e.g., 2.9L) and potentially inline-4 petrol engines, depending on market. Engine Displacement Common: Around 2874cc (2.9L Diesel) is very common for this era Korando. Performance Horsepower Range Diesel: Approximately 95-120 hp for the 2.9L diesel. Torque Range Diesel: Around 190-230 Nm for the 2.9L diesel. Fuel System Fuel Delivery Diesel: Indirect Injection (IDI) or Direct Injection (DI) depending on specific engine codes, often governed by mechanical or electronic fuel pumps. Fuel Type: Diesel and Gasoline (Petrol) 🔧 Transmission Standard Standard Transmission Type: Often a 5-speed manual transmission. Optional Optional Transmission Type: A 4-speed automatic transmission was commonly available as an option. Features Drive Type: Part-time 4WD system with selectable 2WD/4WD modes, often with low-range gearing. 📐 Dimensions Exterior Body Styles: Typically available as a 3-door short-wheelbase SUV and potentially a 5-door long-wheelbase version. Wheelbase Approx: Around 2400-2500 mm for 3-door, and longer for 5-door variants. Weights Curb Weight Approx: 1700-1900 kg, depending on engine and configuration. 🛡️ Safety Features Ratings Crash Test Data Availability: Limited public data for this specific era and model from major testing agencies. Active Features Anti Lock Brakes: Optional on some models, depending on trim and year. Passive Features Airbags: Driver airbag standard on later models, passenger airbag optional. Seatbelts: Standard 3-point seatbelts in front, 2-point or 3-point in rear depending on seating position and year. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player, often 4 or 6 speaker setup. Aftermarket upgrades are common. Navigation: Not typically factory-fitted for this era; aftermarket GPS units were an option. Driver Assistance Cruise Control: Available on higher trim levels or as an option. Connectivity Phone Integration: No factory Bluetooth...
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Ssangyong Korando 1996-2006 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
SsangYong
Model:
Korando
Generation
Model Years Covered:
1996-2006
Codes
Chassis Codes:
KGC100, KGL100 (based on likely generation for this year range)
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road Utility Vehicle
Competitive Analysis
Competitors:
Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, Land Rover Defender (to some extent), Daewoo Korando (earlier models).
Key Features
Design Philosophy:
Rugged body-on-frame construction, capable off-road performance, often available with 4WD.
Target Audience:
Enthusiasts seeking an affordable, capable off-road vehicle, utility-focused buyers.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
SsangYong Korando 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Page Count
Total Pages:
2053
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine block, cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, timing systems, lubrication system, cooling system, intake and exhaust manifolds.
Engine Management:
Fuel injection system (EFI), ignition system, emissions control systems, sensors, actuators, ECU diagnostics.
Transmission Manual:
Gearbox assembly, clutch, shift mechanisms, transfer case operation (if applicable).
Transmission Automatic:
Automatic transmission assembly, torque converter, valve body, transmission control unit (TCU), fluid lines.
Drivetrain:
Front axle, rear axle, driveshafts, differentials, universal joints, constant velocity (CV) joints.
Suspension:
Front suspension (e.g., independent, solid axle), rear suspension (e.g., leaf springs, multi-link), shock absorbers, springs, control arms, stabilizers.
Steering:
Steering gearbox/rack and pinion, power steering system (pump, fluid, lines), steering column, tie rods, steering knuckles.
Brakes:
Front and rear brake systems (disc/drum), master cylinder, brake booster, hydraulic lines, brake calipers, wheel cylinders, parking brake system, ABS (if equipped).
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, body control modules.
Body And Chassis:
Body panels, chassis frame, doors, hood, tailgate, interior trim, body sealing, structural components.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant circuits, controls.
Diagnostics:
On-board diagnostics (OBD) information, diagnostic trouble codes (DTCs), diagnostic procedures.
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication.
Troubleshooting:
System-by-system diagnostic flowcharts, common problems and solutions, symptom-based troubleshooting.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.
Installation:
Procedures for installing new or replacement parts and components.
Adjustment:
Procedures for adjusting various systems, such as brakes, clutch, timing, and emissions.
Disassembly Assembly:
Detailed breakdown and reassembly of major vehicle systems and components.
Wiring Diagrams:
Comprehensive electrical wiring schematics for various vehicle systems.
Special Tool Usage:
Identification and application of specialized service tools required for specific procedures.
Technical Depth
Depth:
Comprehensive 'bumper-to-bumper' coverage suitable for professional mechanics and experienced DIY enthusiasts.
Detail Level:
Includes detailed step-by-step instructions, explanations, pictorial diagrams, exploded views, and photos.
Specifications Data:
Provides service data, specifications lists, tightening torques, checking and adjusting parameters, and allowable limits.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (typically, depending on PDF creation)
Print Quality
Printability:
Yes, all pages are printable.
Resolution:
High resolution, suitable for clear printing.
Binding Type
Binding:
Digital (Instant Download - PDF)
Paper Type
Paper:
N/A (Digital Format)
Compatibility
Operating Systems:
Windows, Mac, Linux OS
Software Requirement:
Adobe Reader or compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Type Common:
Likely inline-4 cylinder diesel (e.g., 2.9L) and potentially inline-4 petrol engines, depending on market.
Engine Displacement Common:
Around 2874cc (2.9L Diesel) is very common for this era Korando.
Performance
Horsepower Range Diesel:
Approximately 95-120 hp for the 2.9L diesel.
Torque Range Diesel:
Around 190-230 Nm for the 2.9L diesel.
Fuel System
Fuel Delivery Diesel:
Indirect Injection (IDI) or Direct Injection (DI) depending on specific engine codes, often governed by mechanical or electronic fuel pumps.
Fuel Type:
Diesel and Gasoline (Petrol)
🔧 Transmission
Standard
Standard Transmission Type:
Often a 5-speed manual transmission.
Optional
Optional Transmission Type:
A 4-speed automatic transmission was commonly available as an option.
Features
Drive Type:
Part-time 4WD system with selectable 2WD/4WD modes, often with low-range gearing.
📐 Dimensions
Exterior
Body Styles:
Typically available as a 3-door short-wheelbase SUV and potentially a 5-door long-wheelbase version.
Wheelbase Approx:
Around 2400-2500 mm for 3-door, and longer for 5-door variants.
Weights
Curb Weight Approx:
1700-1900 kg, depending on engine and configuration.
🛡️ Safety Features
Ratings
Crash Test Data Availability:
Limited public data for this specific era and model from major testing agencies.
Active Features
Anti Lock Brakes:
Optional on some models, depending on trim and year.
Passive Features
Airbags:
Driver airbag standard on later models, passenger airbag optional.
Seatbelts:
Standard 3-point seatbelts in front, 2-point or 3-point in rear depending on seating position and year.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, often 4 or 6 speaker setup. Aftermarket upgrades are common.
Navigation:
Not typically factory-fitted for this era; aftermarket GPS units were an option.
Driver Assistance
Cruise Control:
Available on higher trim levels or as an option.
Connectivity
Phone Integration:
No factory Bluetooth or smartphone integration; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on engine type and driving conditions (refer to manual for exact specification).
Timing Belt Replacement:
If equipped with a timing belt, typically every 80,000-100,000 km (crucial for diesel engines).
Fluid Specifications
Engine Oil Type:
API CG-4 or CH-4 grade for diesel engines (e.g., 15W-40 or 10W-40). Petrol engines would require API SG/SH or higher (e.g., 10W-30 or 5W-30).
Coolant Type:
Ethylene glycol-based antifreeze, mixed with distilled water (e.g., 50/50 mix). Specific SsangYong approved coolant recommended.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron III or equivalent automatic transmission fluid (ATF).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch wear, exhaust system corrosion, suspension bushings, diesel injector pump issues (common on older diesels), electrical connectors.
Specific Model Concerns:
Rust on body panels and chassis, especially in coastal or road salt-prone areas. Potential for injector pump failure on high-mileage diesel models.
📚 Vehicle History
Brand Heritage
Brand Origin:
SsangYong Motor Company, South Korea.
Model Evolution
Korando Lineage:
The Korando nameplate has a long history dating back to the 1970s, originally licensed from Jeep CJ-7 designs. The 1996-2006 generation is a significant evolution from its predecessors.
Production
Production Period:
This generation ran for a considerable period, with this manual covering up to 2006, indicating updates and facelifts within this timeframe.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Limited widely publicized industry awards specifically for this generation of Korando, but was recognized for its ruggedness and off-road capability in its market segment.
Ratings
Consumer Ratings General:
Mixed consumer reviews, often praising its value for money and off-road prowess, but sometimes noting reliability concerns or build quality compared to Japanese rivals.
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