2001-2016 SsangYong Rexton I Service & Repair Manual

Labor Time Guide (Chairman, Korando, Musso, Musso sports, Rexton, Stavic) A - 1 D - 19 G - 103 2 - 177 3 - 213 4 - 221 5 - 251 6 - 319 7 - 335 8 - 355 9 - 369 10 - 513 11 - 526 FOREWORD This Labor Time Guide has been prepared for the purpose of implementing the terms of the current Dealer Sales and Service Agreement and is intended solely for the purpose of computing the compensation payable by SsangYong Motor Co.,Ltd. to the authorized SsangYong dealers for the performance of warranty, policy and campaign adjust- ment and other work authorized and performed for the ac- count of SsangYong Motor Co., Ltd. This use of this guide for any other purpose is neither intended not authorized by SsangYong Motor Co., Ltd. Please read the introduction of this guide thoroughly to acquaint with SsangYong warranty system. All time allowances in this guide are subject to change at any time by SsangYong Motor Co., Ltd. based on time studies by the company related to improved methods, techniques or equipment or other advances in the industry. SECTION INDEX PYUNGTAEK, KOREA A. GENERAL INFORMATION 1. ENGINE (D-Diesel, G-Gasoline) 2. SUSPENSION 3. DRIVE LINE & AXLE 4. BRAKES 5. TRANSMISSION & TRANSFER CASE 6. STEERING 7. H.V.A.C (Heating, Ventilation & Air Conditioning) 8. RESTRAINTS 9. BODY & ACCESSORIES 10. PAINT 11. OTHERS

SECTION A GENERAL INFORMATION 1.INTRODUCTION ..................................................................................... 5 2.HOW TO READ THIS MANUAL .............................................................. 6 3.HOW TO USE THIS MANUAL ................................................................ 9 4.PAINT REPAIR ...................................................................................... 10 5.DEFECT CODE ..................................................................................... 11 6.ABBREVIATION .................................................................................... 13 7.MAIN GROUP CODE ............................................................................. 14

GENERAL INFORMATION A 5 1. INTRODUCTION 1-1. PAGE LAYOUT This Labor Time Guide is designed for convenient and accurate use. In order to provide easy location of operations, the layout has been structured in reading sequence with the corresponding illustration. 1-2. TYPES OF OPERATION Major Operation The Labor Operation Codes consist of seven digits. All operation numbers having “0” in the seven digit of operation number are classified as “major” operations. A major operation time allowance is sufficient to do the work described as a single operation. Supplementary Operation (Adds) All operation numbers having an alphabetical letter in the seventh digit of the operation number are classified as “Supplementary” operations. These operations cannot be used as single operation and must be used as additions to the major operation. 1-3. TIME ALLOWANCES The time allowances published in this guide have been determined by performing the operation a sufficient number of times to establish an average time or to determine that a fair and equitable time has been developed. Standard technician’s hand tools and dealer essential and available tools are used in performing time studies. No power operated tools are used for time studies. Procedures outlined in Service Manuals, other Service Publications and standard shop practices are used as a guide when performing the work necessary to establish time allowances. The time allowance includes the actual time required to perform the operation plus an additional allowance to provide for operating variables. Time allowances include time to remove and reinstall manufacturer optiones and accessories but do not include time to remove and reinstall special or aftermarket equipment. “Repair diagnosis” time is include in all published labor time operations when it is required to perform the operation. It is the responsibility of the dealer’s qualified service staff to assist technicians in “customer problem analysis” and “symtom diagnosis”.

A GENERAL INFORMATION 6 2. HOW TO READ THIS MANUAL 1B-D DIESEL ENGINE MECHANICAL 6 111 1 6 7 5 4 3A 3B 2 Opertion Description Operation Code CM MU/MU-S/KO NO. RX - - ST XDi 662 NA,LA XDi 661 NA,LA 662 NA,LA 661 NA,LA 1 2 3 GASKET, CYLINDER HEAD - REPLACE HEAD, CYLINDER - REPLACE HEAD, CYLINDER - OVERHAUL VALVE (ONE CYLINDER) - REPLACE C - Valves (each additional) 1312300 1312500 1312600 1312700 131270C - - - - - - - - - - 5.0 5.0 7.6 7.6 0.1 5.0 5.0 7.6 7.6 0.1 5.0 5.0 7.6 7.6 0.1 5.0 5.0 7.6 7.6 0.1 - - - - - - - - - - ENGINE UNIT 111

GENERAL INFORMATION A 7 Auxiliary Code 0 A B . . . R Description Major operation Supplementary operation 1) Section Refer to the main group code in this chapter. 2) Illustration Number The illustration number corresponds to the reference number on the illustration. 3) Operation Description 3A. Major Operation The description corresponding to each operation number names the parts or component concerned, and describes what kind of operation is to be performed. 3B. Supplementary Operation The description corresponding to each operation number names the parts or component concerned, and describes the additional operation for removing and reinstalling optional equipment such as power steering, air conditioning, etc., when major operation is performed on the vehicle with optional equipment. 4) Operation Code The operation code consist of seven digits. Main group code Basic code Auxiliary code Main Group Code The main group code consists of 3 digits which indicates the area of the vehicle where the repair was performed. Basic Code The basic code is a 3-digit serial number to each specific operation. Auxiliary Code The Auxiliary Code indicates the type of repairs as shown below :

A GENERAL INFORMATION 8 Major Operation The numeric code “0” represents a major operation. Supplementary Operation (ADD) The numerical code “A”~“R” represents supplementary work of where time is required additionally for the incidental repair work of the parts or components related to the originally intended repair. 5) Operation Times The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and 6 minutes). Enter the operation time on the warranty claim in the same manner. 6) Model Code This code represents the vehicle model. Vehicle model CM : Chairman MU : Musso MU-S : Musso Sports KO : Korando RX : Rexton ST : STAVIC 7) Engine Type This designation represents engine types. 2.0 : M161 Gasoline Engine (G20D) 2.3 : M161 Gasoline Engine (G23D) 2.8 : M162 Gasoline Engine (G28D) 3.2 : M162 Gasoline Engine (G32D) 661 NA/LA : OM 661 Diesel Engine 662 NA/LA : OM 662 Diesel Engine XDi : D27DT(Direct Injection Diesel Engine)

GENERAL INFORMATION A 9 1312700 VALVE - REPLACE 7.0 131270C VALVES (EACH ADDITIONAL) 0.1 Operation Time Total 7.1 3. HOW TO USE THIS MANUAL The operation time in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1hour and 6 minutes). Enter the operation time on the warranty claim in this manner. Example : (When supplementary work is performed in addition to the intended repair) Model : CM Major operation : Valve replacement Supplementary Work : Valves (Each Additional) Step 1 : First find ENGINE MECHANICAL – CYLINDER HEAD in MAIN GROUP INDEX and then the page (Engine 1C-15) for valve from among them. Step 2 : On page Engine 1C-15, note the operation code for Valve. (Replacement) Opertion Description Operation Code CM MU/MU-S/KO NO. RX 2.0/2.3 2.8/3.2 ST 2.3 3.2 2.8/3.2 2.0/2.3 2.8/3.2 2.0/2.3 1 2 3 GASKET, CYLINDER HEAD - REPLACE HEAD, CYLINDER - REPLACE HEAD, CYLINDER - OVERHAUL VALVE (ONE CYLINDER) - REPLACE C - Valves (each additional) 1312300 1312500 1312600 1312700 131270C 6.3 6.3 8.4 6.8 0.1 6.3 6.3 8.6 7.0 0.1 5.6 6.3 8.4 8.4 0.1 6.0 6.3 8.6 8.6 0.1 5.6 6.3 8.4 8.4 0.1 6.0 6.3 8.6 8.6 0.1 - - - - - - - - - - Major operation : VALVE - REPLACE 1312700 7.0 Supplementary Work : C - Valves (each additional) 131270C 0.1 Operation Code 1312700 & 131270C Operation Time Total 7.0 + 0.1 = 7.1

A GENERAL INFORMATION 10 4. PAINT REPAIR 4-1. INSTRUCTION The time allowances herein for painting operations are established on the basis of techniques and material required for quality work both in appearance and durability. The basis for determining the paint time allowances is a “Paintable Surface”. 1. After dents have been removed from sheet metal parts and the parts welded they are stored to their neutral shape. 2. Welding and soldering joints, overlapping seams formed by partial replacement and surfaces smoothed with fillers are ground down using P80-120 grain sandpaper. 3. And when the painter does not need to apply more than 3 coats of knife-edge putty to the surfaces to be painted. 4-2. LABOR TIME The time allowances for paint work consider all cases such as material preparation time, actual working process, and material allowances, which are necessary for a proper and professional paint job. It shall be noted material allowances are converted to hours and included in the operation time, also. According to the character of paint process and size of area to be painted, the kinds and quantity of the material will be varied in the course of paint. The material allowances consist of mixed paint and additional material such as masking tape, sanding paper, cleaning solvent and etc. needed for the operation of each step. INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spray sample / repainting time on clear coat / masking / sanding / cleaning / spraying / removing of the masking and polishing. EXCLUDES ; removal and reinstallation of body attaching parts. 4-3. REPAIR TYPE Type COLOR COAT REFINISH POLISHING Description PAINT EXPOSED SURFACES Top-coat entire surface, including small dents that have been straightened(without filling in). Its operation should be used when correcting painting conditions such as thin paint, color mismatch or surface scratches not extending beyond the prime coat. PAINT NEW PART This operation involves sanding out a defect to expose a local area of bare metal, prime locally and then apply color coat. This applies to those paint repairs that require a repair to the prime coat before the color coat is applied. POLISH THE SURFACES 4-4. HOW TO USE OPERATION CODE ON PARTIAL PAINTING Use the operation code of the relevant part and enter “P” on PF column in Ssangyong Claim Report. For example, in case of partial painting on hood in CHAIRMAN model, make out Ssangyong Claim Report as follows; PF OPERATION CODE HOUR P 9836080 3.1

2001-2016 SsangYong Rexton I Service & Repair Manual

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