Ssangyong Korando 1996-2006 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Ssangyong Model: Korando Generation Generation Name: Korando Family II (DJ) Codes Chassis Codes: DJ 👋 Introduction Market Position Market Segment: Compact SUV / Off-roader Competitive Analysis Key Competitors Era: Jeep Cherokee (XJ), Mitsubishi Pajero, Toyota 4Runner, Land Rover Discovery Key Features Body Styles: Covered (likely includes soft-top, hard-top, and potentially wagon variants depending on specific market configurations). Manual Authenticity: Actual Genuine Factory Repair Manual (not third-party). Value Proposition Cost Savings Potential: $50 - $60 per hour savings on shop labor costs by enabling DIY repairs. 📋 Manual Details Coverage Areas Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Hundreds of pages Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Delivery Method: Digital Download File Format: PDF 📖 Manual Coverage Systems Covered Engine Service Repair: Detailed procedures for engine maintenance, diagnostics, and repair, including internal components and overhaul. Transmission Service Repair: Comprehensive guidance on manual and automatic transmission service, repair, and diagnostics. Brake System: In-depth coverage of brake system components, maintenance, repair, and bleeding procedures. Wiring Diagram: Detailed electrical wiring diagrams for all vehicle systems. Electrical System: Diagnosis and repair of all electrical components and circuits, including lighting, ignition, and accessories. Suspension: Coverage of front and rear suspension systems, including component replacement and alignment procedures. Periodic Lubrication: Specific lubrication points, fluid types, and recommended intervals for maintaining vehicle components. Steering: Procedures for steering system maintenance, repair, and alignment. Cooling System: Detailed information on the cooling system, including radiators, water pumps, thermostats, and coolant specifications. Fuel Injection Fuel System: Repair and maintenance procedures for the fuel delivery system, including injectors, fuel pump, and fuel lines. Emission System: Information on emission control systems and diagnostics. Heater Air Conditional: Maintenance and repair of the HVAC system. Engine Control System: Diagnostics and repair of the Engine Control Unit (ECU) and related sensors. Chassis Body: Bodywork repair, chassis straightening, and panel replacement guidance. Restraint System: Information regarding airbags, seatbelts, and related safety components. Interior: Procedures for interior component removal, installation, and repair. Differential Drive: Service and repair of front, rear, and center differentials, and drive shafts. Axle: Detailed procedures for front and rear axle maintenance and repair. General Maintenance: Routine maintenance tasks, checks, and fluid changes. Troubleshooting: Advanced troubleshooting guides to diagnose and resolve common and complex vehicle issues. Procedures Included Diagnostic Procedures: Step-by-step diagnostic routines for all major vehicle systems. Repair Procedures: Detailed instructions for component removal, repair, and reinstallation. Rebuild Procedures: Comprehensive guidance for complete engine, transmission, and differential rebuilds. Installation Procedures: Instructions for installing various replacement parts and accessories. Technical Depth Technical Depth Level: Complete factory-level repair and maintenance information. 📊 Manual Specifications File Format PDF Quality: High Resolution Searchability: Searchable text within the PDF document. Print Quality Printability: Fully printable without restrictions (individual pages or entire manual). Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options Likely: While not explicitly stated, this generation typically offered gasoline and diesel engines. Common gasoline engines included 2.0L and 2.3L inline-4 units. Diesel options often featured 2.3L or 2.9L indirect injection units, and later models might have had 2.5L or 2.9L turbocharged diesels (e.g., OM602 derivatives). Exact engine types would be detailed within the manual. Performance Horsepower Range Estimated: 80-150 HP (dependent on specific engine variant) Torque Range Estimated: 140-250 Nm (dependent on specific engine variant) Fuel System Fuel Delivery Systems: Carbureted or Fuel Injection (MPI/TBI for gasoline), Indirect Injection (IDI) or Common Rail Direct Injection (CRDI) for diesel, depending on engine and model year. 🔧 Transmission Standard Standard Transmission Type: Likely a 5-speed manual transmission. Optional Optional Transmission Type: Likely a 4-speed automatic transmission was available. Features Drivetrain: Part-time 4WD system with selectable high-range and low-range gearing. 📐 Dimensions Exterior Body Styles Available: Often available as a 2-door convertible (soft-top or hard-top) and a 4-door wagon. Weights Curb Weight Range Estimated: 1700 - 2000 kg (depending on configuration) 🛡️ Safety Features Ratings Safety Ratings Era: Safety standards and testing varied significantly during this period. Specific crash test ratings for this model might be limited or unavailable from major global agencies. Active Features Active Safety Features: Anti-lock Braking System (ABS) likely available on higher trims or later models; limited advanced electronic stability systems. Passive Features Passive Safety Features: Seat belts, potentially driver and passenger airbags on later or higher-spec models. 💡 Technology Features Infotainment Infotainment Features Era: Basic AM/FM radio, possibly cassette or CD player. Limited to standard audio systems; no advanced touchscreens or integrated navigation. Driver Assistance Driver Assistance Features: Very limited. Primarily focused on mechanical aspects rather than electronic driver aids. Connectivity Connectivity Features: No integrated Bluetooth or smartphone connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000...
Detailed procedures for engine maintenance, diagnostics, and repair, including internal components and overhaul.
Transmission Service Repair:
Comprehensive guidance on manual and automatic transmission service, repair, and diagnostics.
Brake System:
In-depth coverage of brake system components, maintenance, repair, and bleeding procedures.
Wiring Diagram:
Detailed electrical wiring diagrams for all vehicle systems.
Electrical System:
Diagnosis and repair of all electrical components and circuits, including lighting, ignition, and accessories.
Suspension:
Coverage of front and rear suspension systems, including component replacement and alignment procedures.
Periodic Lubrication:
Specific lubrication points, fluid types, and recommended intervals for maintaining vehicle components.
Steering:
Procedures for steering system maintenance, repair, and alignment.
Cooling System:
Detailed information on the cooling system, including radiators, water pumps, thermostats, and coolant specifications.
Fuel Injection Fuel System:
Repair and maintenance procedures for the fuel delivery system, including injectors, fuel pump, and fuel lines.
Emission System:
Information on emission control systems and diagnostics.
Heater Air Conditional:
Maintenance and repair of the HVAC system.
Engine Control System:
Diagnostics and repair of the Engine Control Unit (ECU) and related sensors.
Chassis Body:
Bodywork repair, chassis straightening, and panel replacement guidance.
Restraint System:
Information regarding airbags, seatbelts, and related safety components.
Interior:
Procedures for interior component removal, installation, and repair.
Differential Drive:
Service and repair of front, rear, and center differentials, and drive shafts.
Axle:
Detailed procedures for front and rear axle maintenance and repair.
General Maintenance:
Routine maintenance tasks, checks, and fluid changes.
Troubleshooting:
Advanced troubleshooting guides to diagnose and resolve common and complex vehicle issues.
Procedures Included
Diagnostic Procedures:
Step-by-step diagnostic routines for all major vehicle systems.
Repair Procedures:
Detailed instructions for component removal, repair, and reinstallation.
Rebuild Procedures:
Comprehensive guidance for complete engine, transmission, and differential rebuilds.
Installation Procedures:
Instructions for installing various replacement parts and accessories.
Technical Depth
Technical Depth Level:
Complete factory-level repair and maintenance information.
📊 Manual Specifications
File Format
PDF Quality:
High Resolution
Searchability:
Searchable text within the PDF document.
Print Quality
Printability:
Fully printable without restrictions (individual pages or entire manual).
Binding Type
Binding Type Digital:
N/A (Digital Download)
Paper Type
Paper Type Digital:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options Likely:
While not explicitly stated, this generation typically offered gasoline and diesel engines. Common gasoline engines included 2.0L and 2.3L inline-4 units. Diesel options often featured 2.3L or 2.9L indirect injection units, and later models might have had 2.5L or 2.9L turbocharged diesels (e.g., OM602 derivatives). Exact engine types would be detailed within the manual.
Performance
Horsepower Range Estimated:
80-150 HP (dependent on specific engine variant)
Torque Range Estimated:
140-250 Nm (dependent on specific engine variant)
Fuel System
Fuel Delivery Systems:
Carbureted or Fuel Injection (MPI/TBI for gasoline), Indirect Injection (IDI) or Common Rail Direct Injection (CRDI) for diesel, depending on engine and model year.
🔧 Transmission
Standard
Standard Transmission Type:
Likely a 5-speed manual transmission.
Optional
Optional Transmission Type:
Likely a 4-speed automatic transmission was available.
Features
Drivetrain:
Part-time 4WD system with selectable high-range and low-range gearing.
📐 Dimensions
Exterior
Body Styles Available:
Often available as a 2-door convertible (soft-top or hard-top) and a 4-door wagon.
Weights
Curb Weight Range Estimated:
1700 - 2000 kg (depending on configuration)
🛡️ Safety Features
Ratings
Safety Ratings Era:
Safety standards and testing varied significantly during this period. Specific crash test ratings for this model might be limited or unavailable from major global agencies.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS) likely available on higher trims or later models; limited advanced electronic stability systems.
Passive Features
Passive Safety Features:
Seat belts, potentially driver and passenger airbags on later or higher-spec models.
💡 Technology Features
Infotainment
Infotainment Features Era:
Basic AM/FM radio, possibly cassette or CD player. Limited to standard audio systems; no advanced touchscreens or integrated navigation.
Driver Assistance
Driver Assistance Features:
Very limited. Primarily focused on mechanical aspects rather than electronic driver aids.
Connectivity
Connectivity Features:
No integrated Bluetooth or smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km or 6 months (refer to manual for specific engine/oil type).
Transmission Fluid Change Interval:
Approximately every 40,000 - 60,000 km for automatic, and as per manual for manual transmissions.
Timing Belt Replacement Interval:
Crucial for many engines; often around 80,000 - 100,000 km. Manual will specify for each engine type.
Fluid Specifications
Engine Oil Type Specification:
API SG/SH/SJ or ACEA A2/A3, viscosity dependent on climate (e.g., 10W-30, 15W-40 for gasoline; 5W-40, 10W-40 for diesel - refer to manual).
Coolant Type:
Ethylene Glycol based antifreeze/coolant (typically green or blue).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Issues Reported:
Potential issues include corrosion on the chassis and bodywork, suspension wear (bushings, ball joints), electrical gremlins, and issues related to aging diesel fuel injection systems if equipped. Overheating can be a concern if the cooling system is not maintained. Clutch wear on manual transmissions.
📚 Vehicle History
Brand Heritage
Ssangyong Heritage Focus:
SsangYong, a South Korean manufacturer, has a history of producing rugged, off-road-oriented vehicles, often leveraging partnerships and licensed technologies (e.g., Mercedes-Benz diesel engines in earlier models).
Model Evolution
Korando Family Evolution:
The Korando nameplate has a long history, with the Family II (DJ) model being a derivative of the Korando/Korando Family series, known for its utilitarian design and off-road capability. It succeeded earlier generations and was produced for an extended period, receiving minor updates.
Production
Production Period:
1983 - 2006 (for the Korando Family series, with the DJ generation covering the specified years).
Manufacturing Locations:
South Korea
🏆 Awards & Recognition
Recognitions
Award Recognition Type:
Specific awards or recognitions for this model are not widely documented in mainstream automotive media. Its appeal was primarily in its ruggedness and off-road capability at a competitive price point.