Ssangyong Labor Time Guide For Services

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Labor Time Guide

(Chairman, Korando, Musso, Musso sports, Rexton, Stavic)

SECTION INDEX

A. GENERAL INFORMATION A - 1

1. ENGINE D - 19
FOREWORD (D-Diesel, G-Gasoline) G - 103

This Labor Time Guide has been prepared for the purpose 2. SUSPENSION 2 - 177
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 3. DRIVE LINE & AXLE 3 - 213
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- 4. BRAKES 4 - 221
count of SsangYong Motor Co., Ltd.
This use of this guide for any other purpose is neither
5. TRANSMISSION &
intended not authorized by SsangYong Motor Co., Ltd. 5 - 251
Please read the introduction of this guide thoroughly to
TRANSFER CASE
acquaint with SsangYong warranty system.
6. STEERING 6 - 319
All time allowances in this guide are subject to change at
any time by SsangYong Motor Co., Ltd. based on time
7. H.V.A.C (Heating, Ventilation
studies by the company related to improved methods, 7 - 335
techniques or equipment or other advances in the industry.
& Air Conditioning)

8. RESTRAINTS 8 - 355

9. BODY & ACCESSORIES 9 - 369

10. PAINT 10 - 513

PYUNGTAEK, KOREA

11. OTHERS 11 - 526

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 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

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”.

5
A GENERAL INFORMATION

2. HOW TO READ THIS MANUAL

1B-D DIESEL ENGINE MECHANICAL

111

6
7 6

ENGINE UNIT 111

CM MU/MU-S/KO RX ST
Operation
NO. Opertion Description 661 662 661 662
Code - - XDi XDi
NA,LA NA,LA NA,LA NA,LA
1 GASKET, CYLINDER HEAD - REPLACE 1312300 - - 5.0 5.0 5.0 5.0 - -
2 HEAD, CYLINDER - REPLACE 1312500 - - 5.0 5.0 5.0 5.0 - -
HEAD, CYLINDER - OVERHAUL 1312600 - - 7.6 7.6 7.6 7.6 - -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 - - 7.6 7.6 7.6 7.6 - -
C - Valves (each additional) 131270C - - 0.1 0.1 0.1 0.1 - -

2 3B 3A 4 5

6
 GENERAL INFORMATION A

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 :

Auxiliary Code Description

0 Major operation
A
B
.
Supplementary operation
.
.

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A GENERAL INFORMATION

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)

8
 GENERAL INFORMATION A

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)

1312700 VALVE - REPLACE 7.0

131270C VALVES (EACH ADDITIONAL) 0.1
Operation Time Total 7.1

Operation CM MU/MU-S/KO RX ST
NO. Opertion Description
Code 2.0/2.3 2.8/3.2 2.0/2.3 2.8/3.2 2.0/2.3 2.8/3.2 2.3 3.2
1 GASKET, CYLINDER HEAD - REPLACE 1312300 6.3 6.3 5.6 6.0 5.6 6.0 - -
2 HEAD, CYLINDER - REPLACE 1312500 6.3 6.3 6.3 6.3 6.3 6.3 - -
HEAD, CYLINDER - OVERHAUL 1312600 8.4 8.6 8.4 8.6 8.4 8.6 - -
3 VALVE (ONE CYLINDER) - REPLACE 1312700 6.8 7.0 8.4 8.6 8.4 8.6 - -
C - Valves (each additional) 131270C 0.1 0.1 0.1 0.1 0.1 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

9
A GENERAL INFORMATION

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 allow-
ances 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, clean-
ing 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 Description
COLOR COAT 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.
REFINISH 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.
POLISHING 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

10
 GENERAL INFORMATION A

5. DEFECT CODE
5-1. NATURE CODE

N01 Hard start, no start N43 Excessive shock

N02 Poor idle N44 Poor release
N03 Surge, hesitate, stumble N45 Unusual tire wear
N04 Engine noise, engine knoking noise N46 Misaligned or mismatched
N05 Choke malfunction N47 Weak
N06 Engine stalled (general) N48 Hard to turn
N07 Excessive fuel consumption N49 Impossible to turn
N08 Excessive oil consumption N50 Vehicle bouncing
N09 Overheated N51 Deteriorated
N10 Shift shock N52 Distorsion, rainbow, waving
N11 Engine run-on N53 Color mismatched
N12 Flooded, overflowing N54 Defective chrom plate, defective painting
N13 Poor acceleration, uneven acceleration N55 Rust, corrosion, perforation
N14 Abnormal combustion N56 Glazed
N15 Lack of engine power N57 Loose, poor fit
N16 Percolation N58 Bubbles
N17 Improper exhaust gas (black smoke, white smoke) N59 Vehicle vibration
N18 Backfire, afterfire N60 Excessive vibration
N19 Vapor lock N61 Dead battery
N20 Blocked N62 Inaccurate (meter, gauge, etc.)
N21 Shuddering, pulsation, vibration, chattering N63 Poor sound (horn, radio, etc.)
N22 Slippage (slipping) N64 Overcharged, discharged
N23 Difficult engagement N65 Electrical failures
N24 Difficult disengagement N66 Blown fuse
N25 Abnormal shifts N67 Warning light on
N26 Impossible shifts N68 Intermittent operation
N27 Squeaking, squealing, abnormal(wind)noise N69 Pulls to left or right
N28 Dragging N70 Poor AM reception / interference
N29 Pulls N71 Oil leak, oil entering
N30 Stalled while driving N72 Water leak, water entering
N31 Stalled while idling N73 Leaks-other (air, fuel, refrigerant, vacuum)
N32 Stalled between shifts N74 Poor FM reception / interference
N33 Stalling during sudden braking N75 Radio / CD does not operate properly
N34 Fails to reach normal operating temperature N76 Tape deck does not operate properly
N35 RPM too low N77 Improper memory
N36 RPM too high N78 Improper volume control
N37 Jumping-out N80 Head lamp improperly aimed
N38 Improper synchronizing N82 Loosening, failing-off, sagged
N39 Oil diluted N83 Gas leak, gas entering
N40 Misfire N84 Improper opening and/or closing
N41 Sponge pedal N85 Grabbed
N42 Unstable steering N86 Poor maneuverability

11
A GENERAL INFORMATION

N87 Insufficient brake N94 Special policy

N88 Brake judder N95 Glass cracked
N90 Color rainbow, color waving N96 Glass broken
N91 Interference or hitting N97 Glass chipped
N92 Inoperative N98 Glass scratched
N93 High/low operating effort N99 Undefined

5-2. CAUSE CODE

R01 Scored, scratched or chipped R19 Improperly machined

R02 Frozen (temperature) R20 Faulty casting
R03 Peeling, comimg-off R21 Improper clearance, back lash, free play
R04 Rusty, corroded R22 Lack of lubricants
R05 Split, cut or torn R23 Improper welding or soldering, welding or solder-
ing omitted
R06 Broken or cracked R24 Improper tightening, fit or assembly
R07 Porous, pin holes, cavity R25 Sticks, binds, seized
R08 Bent, kinky, twisted, distorted, wraped or wrinkled R26 Foreign material, clogged
R09 Stripped - bolts, holes, nuts R27 Improper sealing, sealer omitted or skipped
R10 Soiled R28 Improper adjustment
R11 Weakened, loss of tension or resilience R31 Incorrect part
(spring, cushion, etc.)
R12 Abnormal wear R32 Improperly installed
R13 Out of balance R33 Improperly routed
R14 Out of round R34 Missing part
R15 Loose or improper connection R35 Flaw in material
R16 Open circuit or short circuit R36 Contaminants
R17 Burnt or burned - out R99 Undefined
R18 Grounded or shorted

5-3. PAINT CODE

P01 Oversprayed, drip P19 Atmospheric fallout

P02 Undersprayed, bare P20 Polishing mark, sanding mark
P03 Color mismatched P21 Touch up
P04 Low Gloss P22 Dust, dirt
P05 Mottled, cloudy P23 Poor welding
P06 Sags or runs P24 Rust
P07 Pin hole P25 Blistered
P11 Peeling, scaling P26 Chipped
P12 Orange peel P27 Cracked
P13 Slow drying P30 Surface scratch
P14 Thin no paint P31 Scab corrosion
P15 Wavy P32 Dent
P16 Tape mark, touch mark P33 Rust perforation
P17 Chemical damage P34 Discolored, faded
P18 Acid rain P99 Undefined

12
 GENERAL INFORMATION A

6. ABBREVIATION
A/C Air conditioning MAP Manifold absolute pressure
ABD Antilock brake differential MAT Manifold air temperature
ADJ Adjust M/T Manual transaxle
ASSY Assembly OH Overhaul
A/T Auto transaxle PLA Plating
CC Color coat print POL Polishing
CHK Check RAD Radiator
CLN Clean REF Refinish paint
DOHC Double overhead camshaft REKES Remote keyless entry system
ECS Electrical control system RI Reinstall
EGR Exhaust gas recirculation RP Replacement
IAC Idle air control TPS Throttle position sensor
I/P Instrument panel T/C Transfer case
L.C.R.V Load conscious reducing valve T.O.D Torque on demand

13
A GENERAL INFORMATION

7. MAIN GROUP CODE

The first 3 digits of 7 digit code classify the units to be serviced into main groups.

SECTION SUB - SECTION MAIN GROUP CODE PAGE

1. ENGINE 1B-D Disel Engine Mech. 111 Engine unit (21p)
113 Belt system
121 Engine block
122 Crankshaft & piston
123 Oil pan & pump
131 Cylinder head
132 Cam support & shaft
133 Timing cover & chain drive
136 Injection pipe
138 Engine & transaxle mount
139 Vacuum system
1D-D Engine Cooling 141 Radiator (47p)
143 Cooling fan
144 Oil cooler
145 Radiator hose & pipe
148 Thermostat & water pump
1E-D Engine Electrical 154 Alternator unit (59p)
156 Starter
157 Battery
158 Fuse & relay
1F-D Engine Controls 170 Fuel filter line (69p)
171 Fuel tank
172 Fuel line
174 Injection pump
182 Accelerator control
1G-D Engine Intake & Exhaust 190 Common rail system (83p)
191 Air intake system
193 Intake manifold
194 Exhaust manifold
196 Exhaust pipe line
197 Turbo charger assembly
198 Sensors
1C-G Gasoline Engine Mech. 111 Engine unit (105p)
113 Belt system
121 Engine block
122 Crankshaft & piston
123 Oil pan & pump
131 Cylinder head
132 Cam support & shaft
133 Timing cover & chain drive
138 Engine & transaxle mount
139 Vacuum system

14
 GENERAL INFORMATION A

SECTION SUB - SECTION MAIN GROUP CODE PAGE

1. ENGINE 1D-G Engine Cooling 141 Radiator (127p)
143 Cooling fan
144 Oil cooler
145 Radiator hose & pipe
148 Thermostat & water pump
1E-G Engine Electrical 151 Ignition cable (139p)
154 Alternator unit
156 Starter
157 Battery
158 Fuse & relay
1F-G Engine Controls 171 Fuel tank (151p)
172 Fuel line & oil line
173 Canister & fuel vacuum
181 Fuel injection
182 Accelerator control
186 Emission control
1G-G Engine Intake & Exhaust 191 Air intake system (167p)
193 Intake manifold
194 Exhaust manifold
196 Exhaust pipe line
2. SUSPENSION 2C Front Suspension 213 Knuckle & hub (179p)
214 Front shock absorber
215 Control arm
216 Torsion bar
217 ECS
218 Sub frame
219 EAS
2D Rear Suspension 231 Rear axle & stabilizer (197p)
232 Rear shock absorber
233 Steering damper
234 Sub frame
2E Tires & Wheel 241 Wheels (209p)
242 TPMS
3. DRIVE LINE & 3A Drive Line & Axle 321 Axle shaft parts (215p)
AXLE 323 Propeller shaft
4. BRAKES 4A Hydraulic Brake 425 Brake pipe (223p)
428 Brake pedal & mount
4B Master Cylinder & Booster 431 Master cylinder & booster (229p)
4D Front Brake 445 Front brake (233p)
4E Rear Brake 456 Rear brake (237p)
4F Anti-Lock Brake System 462 ABS system (243p)
4G Parking Brake 478 Parking brake (247p)
479 EPB

15
A GENERAL INFORMATION

SECTION SUB - SECTION MAIN GROUP CODE PAGE

5. TRANSMISSION 5A Auto Transmission Controls 519 Auto Transmission Controls (255p)
& TRANSFER 5B BTR M74 Auto Transmission 541 BTR M74 I (259p)
CASE
542 BTR M74 II
543 BTR M74 III
544 BTR M74 IV
5C W4A040 Auto Transmission 546 W4A040 A/T I (269p)
547 W4A040 A/T II
548 W4A040 A/T III
549 W4A040 A/T IV
5D W5A330 Auto Transmission 551 W5A330 A/T I (281p)
556 W5A330 A/T II
557 W5A330 A/T III
558 W5A330 A/T IV
559 W5A330 A/T V
5E Five-Speed Manual 561 Manual Transmission (293p)
Transmission 563 Transmission gear
566 Gear shift cover & fork
569 Shift control
5F Clutch 581 Clutch parts (303p)
582 Hydraulic clutch
583 Clutch pedal
5G Transfer Case 592 Transfer case (part time) (311p)
593 T.O.D
595 Transfer case (full time)
6. STEERING 6A Power Steering System 621 Power steering gear (321p)
623 Power steering pipe line
6E Steering Wheel & Column 641 Steering wheel (327p)
643 Steering column
647 Tie rod
7. H.V.A. C (Heating, 7A H.V.A.C (Air Distribution) 711 Air distribution (337p)
Ventilation & Air 713 Evaporator
Conditioning)
714 Blower
7B H.V.A.C (Control) 732 Compressor (345p)
733 Compressor mount
734 A/C hose & pipe line
735 A/C control switch & sensor
8. RESTRAINTS 8A Seat Belts 812 Front seat belt (357p)
822 Rear seat belt
8B S.R.S (Supplemental Inflatable 832 Air bag system (363p)
Restraints) 833 Immobilizer
9. BODY & ACCES- 9A Body Wiring System 911 Wiring harness (371p)
SORIES 9B Lighting System 916 Front lamp (377p)
918 Rear lamp

16
 GENERAL INFORMATION A

SECTION SUB - SECTION MAIN GROUP CODE PAGE

9. BODY & ACCES- 9D Wiper & Washer System 921 Washer system (383p)
SORIES 923 Wiper system
9E Inst. Driver System 925 Instrument cluster (389p)
9F Audio & Anti-theft System 928 Electrical parts (393p)
929 Stics & auto cruise
9G Interior Trim 931 Instrument panel (407p)
932 Switch
933 Instrument parts
934 Console
935 Front door trim
936 Rear door trim
938 Pillar trim
939 Floor carpet & panel
9H Seats 941 Front seat (431p)
942 Rear seat
9L Glass & Mirrors 946 Glass & outside mirrors (437p)
9M Exterior Parts 951 Emblem & lettering (443p)
952 Mud guard
9O Bumpers & Fascias 956 Front bumper (451p)
957 Rear bumper
9P Doors 961A Front door & lock (457p)
961B Front window lifter
961C Front weatherstrip
963A Rear door & lock
963B Rear window lifter
963C Rear weatherstrip
965 Electric door lock
966 Fuel filler lock
967 Trunk lid lock & tailgate lock
968 Car lock
9Q Roof 971 Headlining & roof panel (479p)
972A Sunshade & inside mirror
972B Sun roof
9R Body Front End 973 Hood panel (489p)
974 Front panel
975 Fender panel
976 Dash panel & cowl
977 Grille
9S Body Rear End 978 Trunk lid panel & spoiler (503p)
979 Side trim
10. PAINT 10A PAINT - CHAIRMAN LIMOUSINE, CHAIRMAN (515p)
MUSSO & MUSSO SPORTS
KORANDO
REXTON
STAVIC
11. OTHERS 11 Others Others (526p)

17
 SECTION 1-D

DIESEL ENGINE

1B-D. DIESEL ENGINE MECHANICAL .................................................... 21

1D-D. ENGINE COOLING ....................................................................... 47
1E-D. ENGINE ELECTRICAL .................................................................. 59
1F-D. ENGINE CONTROLS .................................................................... 69
1G-D. ENGINE INTAKE & EXHAUST ...................................................... 83
Ssangyong Labor Time Guide For Services
Full download: http://manualplace.com/download/ssangyong-labor-time-guide-for-services/

1B-D. DIESEL ENGINE MECHANICAL 1B-D

111. ENGINE UNIT .......................................................................... 22

113. BELT SYSTEM ....................................................................... 24

121. ENGINE BLOCK ..................................................................... 26

122. CRANKSHAFT & PISTON ...................................................... 28

123. OIL PAN & PUMP.................................................................... 32

131. CYLINDER HEAD.................................................................... 34

132. CAM SUPPORT & SHAFT...................................................... 36

133. TIMING COVER & CHAIN DRIVE .......................................... 38

136. INJECEION PIPE .................................................................... 40

138. ENGINE & TRANSAXLE MOUNT .......................................... 42

139. VACUUM SYSTEM ................................................................. 44

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