Daewoo Korando 1996-2006 Repair Service Manual

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Tipo: Car

Proveedor:

SKU: 76119

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

Variantes de producto

Descripción

The Daewoo Korando, produced from 1996 to 2006 under the DJ Series designation, is a compact SUV renowned for its body-on-frame construction and 4WD capability, offering robust off-road performance. This generation of the Korando is characterized by its rugged design, drawing lineage from classic Jeep platforms, and positions itself as a capable and value-oriented alternative in the SUV market. It was designed to compete with vehicles like the Jeep Cherokee (XJ) and Toyota 4Runner, emphasizing its utility and durability for both on-road and off-road driving. This comprehensive repair service manual provides essential information for maintaining and repairing the Daewoo Korando DJ Series. It covers a wide array of systems, including engine mechanicals, fuel injection, cooling, lubrication, transmission (manual and automatic), drivetrain, suspension, steering, brakes, and electrical systems. Detailed procedures for maintenance, repair, diagnostics, and troubleshooting are included, along with technical specifications, torque values, and wiring diagrams, making it an invaluable resource for professional technicians and knowledgeable DIY mechanics.

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Korando

Codes

Production Code:

DJ Series (1st Generation)

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road Vehicle

Competitive Analysis

Key Competitors:

Jeep Cherokee (XJ), Toyota 4Runner, Mitsubishi Pajero/Montero, Suzuki Vitara

Key Features

Vehicle Attributes:

Body-on-frame construction, 4WD capability, rugged design, capable off-road performance.

Manual Value Proposition

Target Audience:

Professional technicians, DIY mechanics with basic mechanical and electrical knowledge.

📋 Manual Details

Coverage Areas

Applicable Years:

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

Page Count

Estimated Page Count:

Likely over 1000 pages (typical for a comprehensive factory service manual)

Manual Type

Manual Type:

Repair Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, fuel injection, ignition, cooling, lubrication, emissions control, starting and charging

Transmission Systems:

Manual and Automatic Transmission (removal, installation, overhaul, diagnosis)

Drivetrain Systems:

Transfer case, front and rear axles, driveshafts, CV joints, differentials

Suspension And Steering:

Front and rear suspension components, steering gear, power steering system, wheel alignment

Brake Systems:

Front and rear brakes (disc/drum), hydraulic system, parking brake, ABS system (if equipped)

Electrical Systems:

Battery, charging system, starting system, lighting, instruments, warning indicators, body electrical, power distribution

HVAC Systems:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair

Body And Chassis:

Body construction, panels, doors, glass, interior trim, frame and chassis components

Diagnostics And Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, fault codes

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections

Repair Procedures:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation

Diagnostic Procedures:

Troubleshooting common problems, electrical circuit diagnosis, sensor testing

Technical Specifications:

Torque specifications, clearances, tolerances, fluid capacities, electrical data

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems

Illustrations And Diagrams:

Exploded views, diagrams, and photographs to aid in understanding repair procedures

Technical Depth

Depth Of Coverage:

Comprehensive, covering basic maintenance to complex engine and transmission overhauls, suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Full Printable

Binding Type

Binding Type:

Digital Download (No physical binding)

Paper Type

Paper Type:

N/A (Digital file)

Navigability

Zoom Functionality:

YES (Zoom IN/OUT functionality)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility

Operating System Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Options:

Likely candidates include 2.3L (2279cc) petrol, 2.5L (2507cc) diesel, and potentially later model 2.0L turbo diesel (VM Motori-sourced or Isuzu-sourced depending on market).

Performance

Horsepower Range:

Approximately 100-130 hp for diesel variants, 120-150 hp for petrol variants, depending on exact engine and tuning.

Torque Range:

Diesel engines typically offer higher torque for off-road capability, in the range of 200-270 Nm.

Fuel System

Fuel Delivery:

EFI (Electronic Fuel Injection) for petrol engines, direct injection or rotary pump for diesel engines.

Engine Management

ECU Type:

Likely Bosch or Delphi engine control units, with specific models dependent on engine type.

🔧 Transmission

Standard

Transmission Options:

Typically a 5-speed manual transmission was standard.

Optional

Transmission Options:

A 4-speed automatic transmission was often available as an option.

Features

Transfer Case:

Part-time 4WD system with high and low range gearing, selectable from the cabin.

📐 Dimensions

Exterior

Wheelbase:

Approximately 2400 mm (94.5 inches)

Length:

Approximately 4020-4170 mm (158.3-164.2 inches)

Weights

Curb Weight:

Around 1700-1850 kg (3750-4080 lbs), depending on engine and configuration.

🛡️ Safety Features

Ratings

Crash Test Results:

Limited publicly available crash test data for this specific model and period, typical for vehicles of its era.

Passive Features

Standard Safety Equipment:

Seat belts, potentially driver's airbag on later models or higher trims.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, optional CD player. Aftermarket head unit upgrades common.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature, typically on higher trim levels or later models.

Connectivity

Auxiliary Ports:

Not typically equipped with factory auxiliary input or USB ports; aftermarket solutions required.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 km (3,100 miles) or 6 months for mineral oil, 10,000 km (6,200 miles) or 12 months for synthetic oil, refer to manual for specific grade.

Air Filter Replacement:

Every 20,000-30,000 km (12,500-18,600 miles) or as needed based on driving conditions.

Fuel Filter Replacement:

Diesel: 30,000-40,000 km (18,600-25,000 miles). Petrol: Less frequent, typically checked during scheduled maintenance.

Fluid Specifications

Engine Oil Specification:

Refer to manual for specific API service classification (e.g., API SG, SH, SJ for petrol; CF-4 or CG-4 for diesel) and viscosity grade (e.g., 10W-30, 15W-40).

Coolant Specification:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type (e.g., Asian green or universal pink).

Transmission Fluid Specification Auto:

Dexron III or equivalent automatic transmission fluid (ATF).

Transmission Fluid Specification Manual:

GL-4 or GL-5 gear oil, typically 75W-90 or 80W-90 viscosity. Refer to manual.

Differential Fluid Specification:

Hypoid gear oil, typically SAE 80W-90 or 85W-90 (GL-5). Check for limited-slip differentials if equipped.

Known Issues

Common Wear Items:

CV joints, suspension bushings, ball joints, exhaust system components, clutch (manual transmission), glow plugs (diesel).

Potential Electrical Problems:

Corrosion on electrical connectors, aging wiring harnesses, issues with alternator or starter motor.

Diesel Engine Considerations:

Potential for injector issues, turbocharger problems (if equipped), and glow plug failure, especially in colder climates.

📚 Vehicle History

Brand Heritage

Daewoo Automotive:

Daewoo Motors was a South Korean automobile manufacturer founded in 1982, known for producing a range of vehicles including small cars, sedans, and SUVs. Daewoo faced financial difficulties and its assets were largely acquired by General Motors in 2002.

Model Evolution

Korando Generation:

The 1996-2006 Korando represents the first generation (DJ series) of the nameplate, which was originally based on the technology and platform of the SsangYong Korando (itself a descendant of the classic Jeep CJ).

Production

Manufacturing Location:

South Korea

🏆 Awards & Recognition

Recognitions

Market Positioning:

Positioned as a value-oriented, capable off-road SUV, offering a rugged alternative to more car-like SUVs.