Daewoo Korando 1996-2006 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Korando Product Name: Daewoo Korando 1996-2006 Workshop Service Repair Manual PDF Download Generation Model Generation: First Generation (1996-2006) Codes Chassis Codes: First Generation Korando chassis codes are often associated with the SsangYong Korando lineage, typically prefixed with 'KJ' for the early models. While specific Daewoo-assigned codes for this generation might differ slightly, the underlying structure is derived from SsangYong. 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Competitive Analysis Key Competitors Era: During its production run, the Daewoo Korando competed with vehicles such as the Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, and similar body-on-frame SUVs. Key Features Body Style: Primarily offered as a 2-door convertible or hardtop, and later as a 4-door wagon (station wagon) variant, reflecting its origins as a rugged utility vehicle. Drivetrain Options: Typically featured robust body-on-frame construction with rear-wheel drive or selectable four-wheel drive (4WD) systems, emphasizing off-road capability. 📋 Manual Details Coverage Areas Covered Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Hundreds of Pages (exact count not specified, but described as 'hundreds') Manual Type Type: Workshop Service Repair Manual Purpose: Designed for both the do-it-yourselfer and experienced mechanics to keep the vehicle working properly. Language Language: English Format Format: PDF (Digital Download) Delivery Method: Instant Digital Download via link on checkout page after payment. Platform Compatibility: Compatible with all PC-based Windows operating systems and macOS. Can be saved to hard drive or burned to CD-ROM. 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of engine mechanicals, including cylinder head, block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling, and fuel delivery. Transmission: Detailed procedures for both manual and automatic transmissions, including disassembly, reassembly, adjustments, and fluid specifications. Drivetrain: Coverage of front-wheel drive, rear-wheel drive, and four-wheel drive systems, including differentials, driveshafts, and CV joints. Suspension: Front and rear suspension systems, including shock absorbers, springs, control arms, steering knuckles, and bushings. Steering: Power steering system components, including pump, rack and pinion, steering column, and associated lines and fluids. Brakes: Front and rear brake systems (disc and drum), including hydraulic components, ABS (if applicable), parking brake, and bleeding procedures. Electrical System: Extensive coverage of the vehicle's electrical system, including battery, charging system, starter, lighting, ignition, and accessory circuits. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel filter, and evaporative emission control system. Cooling System: Radiator, water pump, thermostat, cooling fans, hoses, and coolant specifications. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, and pipes. Climate Control: Air conditioning system components, heating system, and ventilation. Body And Chassis: Body panel removal and installation, interior trim, doors, windows, bumpers, and chassis components. Interior Trim And Upholstery: Procedures for removal and installation of interior panels, seats, headliner, and dashboard components. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspection procedures. Major Repairs: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, and exhaust system repair. Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for engine management systems (if applicable), and electrical system diagnostics. Electrical Troubleshooting: Detailed wiring diagrams, circuit tracing procedures, and diagnostic steps for electrical faults. Component Replacement: Step-by-step instructions for replacing individual components, such as sensors, actuators, pumps, and alternators. Adjustments: Procedures for adjusting critical systems like parking brake, clutch pedal (if manual), and ignition timing (if applicable). Engine Timing Adjustment: Includes procedures for setting or checking engine timing, particularly important for diesel engines and ignition systems on gasoline variants. Differential Service: Procedures for servicing front, rear, and transfer case differentials, including fluid changes and potential repairs. Wheel Alignment: Specifications and procedures for checking and adjusting wheel alignment parameters (camber, caster, toe-in). Air Conditioning Service: Detailed steps for air conditioning system maintenance, including refrigerant handling (with safety precautions), component replacement, and leak detection. Technical Depth Depth: Complete factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Covers disassembly to reassembly with critical torque specifications and procedures. Illustrations: Hundreds of detailed illustrations, drawings, and photos to guide through each service and repair procedure. Guidance: Step-by-step instructions, detailed substeps, notes, cautions, and warnings to ensure correct procedure execution. Torque Specifications: Critical torque specifications for all major fasteners and components are provided, essential for proper assembly and preventing damage. Diagnostic Charts: Troubleshooting charts and symptom-to-cause guides to efficiently diagnose problems. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without any restriction. Allows printing of entire manual or specific pages. Binding Type Binding: Digital Download (Printable) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Options: The Korando during this era was offered with a range of engines, often including Isuzu-derived diesel engines and some gasoline options. Common diesel engines include the 2.3L and 2.9L naturally aspirated and turbocharged diesel units. Gasoline options...

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Tags: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Car Cars Daewoo Korando

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Description

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Korando

Product Name:

Daewoo Korando 1996-2006 Workshop Service Repair Manual PDF Download

Generation

Model Generation:

First Generation (1996-2006)

Codes

Chassis Codes:

First Generation Korando chassis codes are often associated with the SsangYong Korando lineage, typically prefixed with 'KJ' for the early models. While specific Daewoo-assigned codes for this generation might differ slightly, the underlying structure is derived from SsangYong.

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Competitive Analysis

Key Competitors Era:

During its production run, the Daewoo Korando competed with vehicles such as the Jeep Cherokee (XJ), Mitsubishi Pajero/Montero, Toyota 4Runner, and similar body-on-frame SUVs.

Key Features

Body Style:

Primarily offered as a 2-door convertible or hardtop, and later as a 4-door wagon (station wagon) variant, reflecting its origins as a rugged utility vehicle.

Drivetrain Options:

Typically featured robust body-on-frame construction with rear-wheel drive or selectable four-wheel drive (4WD) systems, emphasizing off-road capability.

📋 Manual Details

Coverage Areas

Covered Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Page Count

Estimated Page Count:

Hundreds of Pages (exact count not specified, but described as 'hundreds')

Manual Type

Type:

Workshop Service Repair Manual

Purpose:

Designed for both the do-it-yourselfer and experienced mechanics to keep the vehicle working properly.

Language

Language:

English

Format

Format:

PDF (Digital Download)

Delivery Method:

Instant Digital Download via link on checkout page after payment.

Platform Compatibility:

Compatible with all PC-based Windows operating systems and macOS. Can be saved to hard drive or burned to CD-ROM.

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage of engine mechanicals, including cylinder head, block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling, and fuel delivery.

Transmission:

Detailed procedures for both manual and automatic transmissions, including disassembly, reassembly, adjustments, and fluid specifications.

Drivetrain:

Coverage of front-wheel drive, rear-wheel drive, and four-wheel drive systems, including differentials, driveshafts, and CV joints.

Suspension:

Front and rear suspension systems, including shock absorbers, springs, control arms, steering knuckles, and bushings.

Steering:

Power steering system components, including pump, rack and pinion, steering column, and associated lines and fluids.

Brakes:

Front and rear brake systems (disc and drum), including hydraulic components, ABS (if applicable), parking brake, and bleeding procedures.

Electrical System:

Extensive coverage of the vehicle's electrical system, including battery, charging system, starter, lighting, ignition, and accessory circuits.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel filter, and evaporative emission control system.

Cooling System:

Radiator, water pump, thermostat, cooling fans, hoses, and coolant specifications.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, and pipes.

Climate Control:

Air conditioning system components, heating system, and ventilation.

Body And Chassis:

Body panel removal and installation, interior trim, doors, windows, bumpers, and chassis components.

Interior Trim And Upholstery:

Procedures for removal and installation of interior panels, seats, headliner, and dashboard components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspection procedures.

Major Repairs:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, and exhaust system repair.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for engine management systems (if applicable), and electrical system diagnostics.

Electrical Troubleshooting:

Detailed wiring diagrams, circuit tracing procedures, and diagnostic steps for electrical faults.

Component Replacement:

Step-by-step instructions for replacing individual components, such as sensors, actuators, pumps, and alternators.

Adjustments:

Procedures for adjusting critical systems like parking brake, clutch pedal (if manual), and ignition timing (if applicable).

Engine Timing Adjustment:

Includes procedures for setting or checking engine timing, particularly important for diesel engines and ignition systems on gasoline variants.

Differential Service:

Procedures for servicing front, rear, and transfer case differentials, including fluid changes and potential repairs.

Wheel Alignment:

Specifications and procedures for checking and adjusting wheel alignment parameters (camber, caster, toe-in).

Air Conditioning Service:

Detailed steps for air conditioning system maintenance, including refrigerant handling (with safety precautions), component replacement, and leak detection.

Technical Depth

Depth:

Complete factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Covers disassembly to reassembly with critical torque specifications and procedures.

Illustrations:

Hundreds of detailed illustrations, drawings, and photos to guide through each service and repair procedure.

Guidance:

Step-by-step instructions, detailed substeps, notes, cautions, and warnings to ensure correct procedure execution.

Torque Specifications:

Critical torque specifications for all major fasteners and components are provided, essential for proper assembly and preventing damage.

Diagnostic Charts:

Troubleshooting charts and symptom-to-cause guides to efficiently diagnose problems.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Printable without any restriction. Allows printing of entire manual or specific pages.

Binding Type

Binding:

Digital Download (Printable)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

The Korando during this era was offered with a range of engines, often including Isuzu-derived diesel engines and some gasoline options. Common diesel engines include the 2.3L and 2.9L naturally aspirated and turbocharged diesel units. Gasoline options might include 2.0L or 2.2L units, though specific Daewoo badged variants might have had localized engine choices.

Performance

Power Output Range:

Horsepower and torque varied significantly by engine. Diesel engines typically ranged from approximately 70-100 HP for naturally aspirated versions and up to 120-140 HP for turbocharged variants. Gasoline engines would generally be in a similar or slightly higher HP range for their displacement.

Fuel System

Injection Type:

Diesel engines likely utilized indirect injection (IDI) for naturally aspirated versions and direct injection (DI) or common rail (in later iterations of similar engines) for turbocharged variants. Gasoline engines would typically use multi-point fuel injection (MPI).

Engine Code Example

Common Diesel Engine Code Example:

Isuzu C223T (for a 2.3L turbo diesel) or similar Isuzu 4JB1T (for a 2.8L turbo diesel) might be found in variants of this vehicle's lineage.

🔧 Transmission

Standard

Standard Transmission:

Often a 5-speed manual transmission was a standard offering, particularly on lower trims or earlier models.

Optional

Optional Transmission:

A 4-speed automatic transmission was commonly available as an option across various trims and engine configurations.

Features

4Wd System:

Selectable 4WD (4x4) system with high and low range transfer case, enabling drivers to engage four-wheel drive when needed for enhanced traction.

📐 Dimensions

Exterior

Wheelbase Range:

Wheelbase typically around 2,400 - 2,440 mm (94.5 - 96.1 inches) for 2-door models, and longer for 4-door models. Specific measurements would vary.

Track Width Range:

Front and rear track widths would typically be in the range of 1,400 - 1,500 mm (55 - 59 inches), depending on the specific model and wheel/tire combination.

Weights

Curb Weight Range:

Curb weights generally ranged from approximately 1,600 kg to 1,900 kg (3,500 lbs to 4,200 lbs), depending on body style, engine, and equipment.

🛡️ Safety Features

Ratings

Crash Test Information:

Specific official crash test ratings (e.g., NHTSA, Euro NCAP) for Daewoo badged Korandos from this era may be limited or inconsistent compared to more mainstream manufacturers. However, the robust body-on-frame construction provided a degree of inherent structural integrity.

Active Features

Anti-lock Braking System (ABS) was often an optional feature, particularly on higher trim levels or later models, enhancing braking control.

Passive Features

Airbags:

Driver and front passenger airbags were available, becoming more common in later production years. Side airbags were generally not a common feature for this generation.

Seatbelts:

Three-point seatbelts for front occupants, with two-point or three-point belts for rear occupants depending on seating position and body style.

💡 Technology Features

Infotainment

Audio System:

Basic factory-installed audio systems, typically AM/FM radio with cassette player or a single CD player in later models. Speaker count and quality were usually modest.

Driver Assistance

Cruise Control:

Cruise control was generally an optional feature, more commonly found on higher trim levels or later model years.

Connectivity

Connectivity Options:

Limited to basic radio connectivity. Bluetooth, USB, or auxiliary inputs were not standard features in this era, often requiring aftermarket installations.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions. Consult the manual for specific intervals based on engine type and usage.

Transmission Fluid Change:

Manual transmission: check level regularly, change fluid at approximately 50,000 - 80,000 miles (80,000 - 130,000 km). Automatic transmission: check level frequently, change fluid and filter at intervals around 30,000 - 50,000 miles (50,000 - 80,000 km).

Coolant Flush:

Coolant flush and replacement typically recommended every 2 - 3 years or 40,000 - 60,000 miles (64,000 - 96,000 km).

Fluid Specifications

Engine Oil:

Varies by engine, but common recommendations for diesel engines include API CG-4 or CH-4 spec 15W-40 or 10W-40. Gasoline engines might use API SN 5W-30 or 10W-30. Always check the manual for precise specifications.

Transmission Fluid:

Manual: GL-4 or GL-5 gear oil (e.g., 75W-90 or 80W-90). Automatic: DEXRON-III (or equivalent) automatic transmission fluid (ATF).

Coolant:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific color or type requirements (e.g., traditional green or OAT).

Known Issues

Common Wear Items:

Due to age and intended use, common wear items can include suspension bushings, shock absorbers, exhaust components, clutch wear (manual), and potential for rust in older units. Diesel engines may require glow plug maintenance.

Electrical Gremlins:

Like many vehicles of this era, intermittent electrical issues related to wiring harnesses, grounding points, or aging switches can occur. The manual's wiring diagrams are crucial for diagnosis.

Filter Part Numbers

Oil Filter Example:

Specific part numbers vary greatly by engine. For example, an engine similar to the Isuzu 4JB1T might use a filter like the Fram PH5055 or equivalent. The manual will provide specific OEM or equivalent part numbers.

📚 Vehicle History

Brand Heritage

Daewoo Context:

Daewoo Motors, a South Korean manufacturer, was active from the late 1980s until its acquisition by General Motors in 2002. The Korando was a significant model in its SUV lineup, often leveraging technology and platforms from its affiliations (initially with Isuzu).

Model Evolution

Ssangyong Lineage:

The Korando's lineage traces back to the SsangYong Korando, which itself was inspired by the Jeep CJ series. Daewoo acquired SsangYong Motor Company in 1998, leading to the rebranding of some SsangYong vehicles under the Daewoo name.

Production

Manufacturing Location:

Primarily manufactured in South Korea by SsangYong Motor Company, with Daewoo branding applied for specific markets after Daewoo's acquisition.

🏆 Awards & Recognition

Recognitions

Off Road Capability:

While not a recipient of numerous consumer awards in the traditional sense, the Korando's robust chassis and 4WD system were often recognized by off-road enthusiasts for its go-anywhere capability, especially in its early iterations.

Ratings

Reliability Perception:

Reliability perception varied. While the core mechanicals (especially diesel engines derived from Isuzu) were generally considered robust, build quality and electrical systems could sometimes be points of concern, typical for vehicles from this period and brand's market position.