1996-2006 Ssangyong Korando Service Repair Workshop Manual

This is the COMPLETE Service and Repair Manual for the 1996-2006 Ssangyong Korando Service Repair Workshop Manual. It covers every single detail.

SsangYong Korando Service Repair Workshop Manual PDF VEHICLE/EQUIPMENT INTRODUCTION: The SsangYong Korando is a compact SUV produced by the Korean automaker SsangYong Motor Company. The name Korando derives from the phrase Korea Can Do reflecting the national pride in Korean automotive manufacturing capability. The second generation Korando produced from 1996 through 2006 represents a body-on-frame sport utility vehicle with genuine off-road capability rather than the car-based crossover design that later dominated the compact SUV segment. These Korando models utilized Mercedes-Benz licensed engine technology including the OM662 2.3-liter turbo diesel and the OM601 2.9-liter turbo diesel powerplants along with gasoline options from SsangYong own engine development program. The Mercedes-derived diesel engines are renowned for their mechanical simplicity, durability under harsh operating conditions, and straightforward serviceability that makes them ideal for markets where dealer network support is limited. The Korando features a ladder frame chassis with rigid rear axle and independent front coil spring suspension providing wheel articulation for off-road terrain combined with on-road stability. Part-time four-wheel drive with a transfer case providing high and low range gearing is standard equipment, along with a locking center differential for serious trail capability that most modern crossovers cannot match. SERVICE AND REPAIR SCOPE: - Mercedes-derived OM diesel engine service including injection pump timing - Turbocharger removal and wastegate actuator calibration - Manual and automatic transmission removal with transfer case separation - Part-time 4WD transfer case rebuild with chain tensioner inspection - Rigid rear axle differential overhaul with bearing preload setting - Independent front suspension ball joint and control arm bushing replacement - Brake system master cylinder, proportioning valve, and drum brake adjustment - Engine control module diagnostics for EFI and electronic diesel control systems - HVAC system heater core and blower motor replacement - Body mount bushing replacement and frame-to-body alignment TECHNICAL SPECIFICATIONS: - Engine options: Mercedes-Benz OM662 2.3L turbo diesel, OM601 2.9L turbo diesel, and gasoline variants - Diesel type: Indirect injection with turbocharger and intercooler - Transmission: 5-speed manual or 4-speed automatic - Drive: Part-time 4WD with transfer case high-low range - Front suspension: Independent coil spring with double wishbone - Rear suspension: Rigid axle with leaf springs - Steering: Recirculating ball power steering - Front brake: Ventilated disc - Rear brake: Drum - Wheelbase: 2480 mm short wheelbase version DIAGNOSTIC INFORMATION: - Diesel injection pump timing verification using dial indicator on number one cylinder at TDC - Turbocharger boost pressure measurement with wastegate response testing - Transfer case chain stretch measurement to determine replacement necessity - Injec

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