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 1996-2006 Service Repair Workshop Manual PDF The SsangYong Korando was a rugged Korean-built SUV that carved out a niche for itself in the compact four-wheel drive market. Produced across a decade-long run, the Korando offered body-on-frame construction, part-time four-wheel drive with transfer case and robust suspension suited to off-road conditions. The vehicle was powered by Mercedes-Benz licensed diesel engines and later SsangYongs own powerplants. Known for its utilitarian character and competitive pricing, the Korando appealed to buyers who needed genuine off-road capability without the premium costs of Japanese competitors. The 1996 through 2006 period covered the second generation KJ Korando, which featured updated styling and improved interior comfort while retaining the ladder frame and leaf-spring rear suspension that gave it genuine go-anywhere capability. VEHICLE/EQUIPMENT INTRODUCTION: The SsangYong Korando KJ generation served as the brands most globally successful model during the late 1990s and early 2000s. Built with a sturdy ladder frame chassis and body-on-frame construction, it was a genuine off-road vehicle. Engine options included Mercedes-Benz OM602 2.9-liter five-cylinder turbo diesel and later SsangYong D27DTI engines, both known for durability. The transfer case offered high and low range selection, and the leaf spring rear suspension handled heavy loads and rough terrain. The Korando found markets in Europe, Asia, Australia and the Middle East. SERVICE & REPAIR SCOPE: - Mercedes-Benz derived diesel engine overhaul and timing chain service - Turbocharger inspection, boost pressure testing and intercooler cleaning - Manual transmission gearbox overhaul and transfer case service - Clutch hydraulic system overhaul and release bearing replacement - Drive shaft U-joint and CV joint rebuild - Front axle locking hub mechanism inspection and repair - Leaf spring replacement and rear shock absorber service - Power steering pump and recirculating ball steering box overhaul - Brake disc and pad replacement with ABS sensor testing - Electrical harness repair and relay identification - Window regulator and door lock mechanism service - Heater blower motor and HVAC actuator replacement TECHNICAL SPECIFICATIONS: - Engine: Mercedes-Benz OM602 2.9 TD, SsangYong D27DTI - Transmission: 5-speed manual, part-time 4WD transfer case - Front suspension: Independent, torsion bar - Rear suspension: Leaf spring, live axle - Brakes: Ventilated front discs, rear discs or drums - Steering: Recirculating ball, power-assisted - Electrical: 12-volt system DIAGNOSTIC INFORMATION: - Diesel engine smoke issues: black smoke indicates turbo boost leak or air filter restriction, white smoke suggests injector timing or head gasket, blue indicates oil consumption - Transfer case engagement failure: inspect shift fork wear, check vacuum actuator or electric motor, verify front driveshaft U-joints - Rough idle on cold start: check glow plug rel

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