720S

1.	DA-RM-01A001-00-001 - Secure/Lift vehicle on platform
2.	DA-RM-03A071-07-002 - Remove/Install access hatch - Luggage bin
3.	Care Point: Depressurise suspension system before disconnecting battery. DA-RM-04B003-00-001 - Fill/Bleed fluid - Suspension system
4.	Care Point: Remove both sides. DA-RM-08N001-07-001 - Remove/Install seat
5.	Care Point: Make sure EPB calipers are in service mode before disconnecting battery. DA-RM-07M003-00-001 - Disconnect/Connect Li-ion battery
6.	DA-RM-02A051-08-001 - Remove/Install panel - Service Cover
7.	DA-RM-02A051-08-002 - Remove/Install panel - Rear deck vent
8.	DA-RM-02A051-08-003 - Remove/Install panel - Engine bay cover
9.	DA-RM-02A056-03-001 - Remove/Install glass - Tailgate - Removable
10.	Care Point: Remove both sides. DA-RM-04B005-01-001 - Remove/Install wheel - Rear
11.	Care Point: Remove both sides. DA-RM-03A076-02-001 - Remove/Install wheel arch liner - Rear
12.	DA-RM-03A075-04-001 - Remove/Install floor panel - Front
13.	DA-RM-01A004-02-001 - Remove/Install floor panel - Engine
14.	Care Point: Remove both sides. DA-RM-03A075-05-002 - Remove/Install floor panel - Rear extension
15.	DA-RM-03A075-05-001 - Remove/Install floor panel - Diffuser
16.	DA-RM-01A004-02-002 - Remove/Install floor panel - Transmission
17.	DA-RM-01A003-01-002 - Remove/Install crossbeam - Transmission floor
18.	DA-RM-05F003-00-001 - Drain/fill - Engine oil
19.	DA-RM-04L001-00-001 - Drain/Fill fluid - Coolant
20.	DA-RM-03A077-00-001 - Drain/Fill fluid - HVAC refrigerant
21.	DA-RM-03A071-10-001 - Remove/Install bumper assembly - Rear
22.	DA-RM-04B002-04-001 - Remove/Install Z-bar - Rear
23.	DA-RM-02A053-03-001 - Remove/Install panel - Airbrake
24.	DA-RM-02A053-04-001 - Remove/Install mechanism - Airbrake
25.	DA-RM-02A051-03-006 - Remove/Install heatshield - Airbrake
26.	Care Point: Remove both sides. DA-RM-02A051-03-004 - Remove/Install panel - Side duct finisher
27.	Care Point: Remove both sides. DA-RM-02A051-03-003 - Remove/Install panel - Dirty air duct
28.	Care Point: Remove both sides. DA-RM-02A051-03-002 - Remove/Install bodyside - Lower
29.	Care Point: Remove both sides. DA-RM-02A051-03-005 - Remove/Install panel - Aero bridge
30.	Care Point: Remove both sides. DA-RM-02A051-03-001 - Remove/Install bodyside - Upper - Left
31.	DA-RM-05E001-02-002 - Remove/Install heatshield - Muffler - Upper
32.	DA-RM-05H001-02-001 - Remove/Install muffler
33.	DA-RM-05E001-02-003 - Remove/Install heatshield - Muffler - Lower
34.	Care Point: Remove both sides. DA-RM-04L001-02-001 - Remove/Install radiator - High temperature
35.	Care Point: Remove both sides. DA-RM-05F002-03-001 - Remove/Install water charge air cooler (WCAC)
36.	Care Point: Remove both sides. DA-RM-05H001-04-001 - Remove/Install sensor - Lambda - Pre-catalyst
37.	Care Point: Remove both sides. DA-RM-05H001-04-002 - Remove/Install sensor - Lambda - Post-catalyst
38.	Care Point: Remove both sides. DA-RM-05H001-01-001 - Remove/Install catalytic converter and link pipe assembly - Left
39.	Care Point: Remove both sides. DA-RM-05E001-02-004 - Remove/Install heatshield - Airguide
40.	DA-RM-02A051-08-004 - Remove/Install heatshield - Deck vent rear
41.	Care Point: Remove both sides. DA-RM-05F002-01-004 Remove/Install duct - airbox to clean air duct
42.	Care Point: Remove both sides. DA-RM-05F002-01-005 - Remove/Install duct - Clean air
43.	Care Point: Remove both sides. DA-RM-05F002-01-006 - Remove/Install duct - Clean air duct to turbo charger
44.	Care Point: Remove both sides. DA-RM-05F002-01-002 - Remove/Install Airbox
45.	DA-RM-05F001-03-001 - Remove/Install pump - Secondary air
46.	DA-RM-01A003-02-002 - Remove/Install bumper beam - Rear
47.	Care Point: Remove both sides. Detach caliper from upright only, do not disconnect fluid hose. DA-RM-04C002-02-001 - Remove/Install brake caliper - Rear
48.	Care Point: Remove both sides. DA-RM-04C004-01-001 - Remove/Install brake caliper - Parking
49.	Care Point: Remove both sides. DA-RM-04C002-03-001 - Remove/Install brake disc cooling duct - Rear
50.	Care Point: Remove both sides. DA-RM-04C002-01-001 - Remove/Install brake disc - Rear
51.	Care Point: Remove both sides. DA-RM-05G004-01-001 - Remove/Install drive shaft
52.	DA-RM-05F003-03-001 - Remove/Install oil filler tube

DANGER!

Risk of death working with lifting platforms!

Care must be taken while working with the lifting platform. Death may occur if a vehicle slips or topples off the lifting platform.

Position the support plates on the lifting platform support points at the same height.

•	Raise the vehicle a few inches first (wheels are still touching the ground) and check the position and fit of the support plates and lift points before raising the vehicle to the full lifted position.
•	Do not raise the vehicle off the lifting platform plates when components are being supported.
•	Centre the vehicle lengthwise and crosswise between the lifting platform columns.
•	Comply with all relevant statutory and accident prevention regulations.

WARNING!

Sharp vehicle parts.

Caused by scraping or cutting.

Always wear protective gloves when working on or near sharp and burred vehicle parts.

•	Repair panels must be deburred.

WARNING!

Risk of explosion, poisoning and injury working with fuel!

Fuels are highly flammable and toxic if inhaled. Fuel vapours are explosive, invisible and spread out at floor level. This vapour is poisonous when inhaled and has an anesthetizing effect in high concentrations. Fuel can cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel.

Observe the national safety precautions and regulations.

•	Keep fuel away from fire, open light or ignition sources.
•	Ensure the work place is adequately ventilated.
•	Never drain or pour in fuels over assembly pits.
•	Store drained fuel in a suitable and sealed vessel.
•	Immediately eliminate any fuel which has flowed out.
•	Conducting work on a vehicle with open flames (e. g. welding etc.).
•	Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs.

WARNING!
Possible fluid spills from vehicle systems during repairs or maintenance. Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours. Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.

Remove engine

Care Point:

If you are replacing the engine on a vehicle that is not fitted with ISG, remove the ISG blanking plate and transfer it to the new engine.

Disconnect ISG hose (1).

Detach clips (2) and disconnect top coolant hoses.

Detach clip (3) and disconnect ventilation hose.

Disconnect fuel feed pipe (4).

Disconnect purge pipe (5).

Disconnect vacuum pipe (6).

Care Point:

Disconnect harness clips and lay aside wiring onto transmission.

Disconnect Powertrain control unit connectors.

Disconnect Transmission control unit connectors.

Remove ground bolt (7) and lay aside cable. (M8x16) 13 Nm

10.

Remove bolt (8) and detach HVAC hoses from drier. (M8x20) 8 Nm

Care Point:

Raise vehicle to carry out all tasks underneath vehicle.

11.

Detach clip (9) and disconnect hose.

12.

Detach 12V supply line cover cap and remove nut (10). (M8) 20 Nm

13.

Remove bolts (11). (M6x16) 3 Nm

14.

Detach clip (12) and disconnect hose.

15.

Detach clip (13) and disconnect heater hose.

16.	Remove bolts (14). (M6x16) 8 Nm
17.	Disconnect oil tank hose (15) from engine.
18.	Remove bolts (16). (M6x16) 8 Nm
19.	Disconnect oil hose (17) from engine.

20.	Remove clip (18) and disconnect hose.
21.	Remove clip (19) and disconnect hose.
22.	Remove clip (20) and disconnect hose.
23.	Remove clip (21) and disconnect hose.

Care Point:

Complete steps on both sides of vehicle where required.

Care Point:

Use a suitable tray to catch the fluid where required.

24.

Remove bolt (22). (M5x35) 5 Nm

25.

Disconnect hose.

26.

Remove bolts (23). (M5x30) 5 Nm

27.

Disconnect hoses.

28.	Release lock and detach displacement sensor link rod (24) from lower wishbone.
29.	Disconnect wheel speed sensor (25).
30.	Disconnect rear suspension accelerometer (26).
31.	Disconnect the three actuator electrical connectors (27).
32.	Detach EPB harness from lower wishbone.

33.

Remove drive shaft nut (28). 260 Nm

34.

Disconnect track rod (29). (M14) 90 Nm

35.

Remove damper bolts (30). (M10x40) 57 Nm

Care Point:

With the aid of another technician, supporting the suspension assembly.

36.

Remove upper wishbone bolts (31). (M10x30) 57 Nm

37.

Remove lower wishbone bolts (32). (M10x30) 57 Nm

Care Point:

Suspension removed as an assembly.

38.

Remove suspension assembly.

39.

Remove Drive shafts. DA-RM-05G004-01-001 - Remove/Install drive shaft

Care Point:

Counter hold union when disconnecting hoses.

40.

Disconnect airbrake hoses (33) from airbrake mechanism. 20 Nm

Care Point:

Left hand hose has a dot mark above union.

41.

Disconnect airbrake hoses (34) from transmission. 26 Nm

42.	Remove clamp bolt (35). (M6x16) 8 Nm
43.	Remove suspension hoses (36) and airbrake hose / valve block assembly (37) from vehicle.

44.

Disconnect electrical connectors (38) and lay aside harness onto transmission.

45.

Disconnect electrical connectors (39) and lay aside harness onto transmission.

46.	Remove bolt (40) and disconnect clutch cooler pipe. (M6x16) 8 Nm
47.	Release clamp (41) and disconnect transmission cooler pipe.

48.	Remove bracket bolt (42). (M5x10) 8 Nm
49.	Remove bolt (43) and disconnect pipe from engine. (M6x16) 8 Nm

50.	Remove bolts (44).(M6x16) 8 Nm
51.	Disconnect and remove transmission cooler pipes from vehicle.
52.	Remove ground bolt (45).(M8x16) 13 Nm

53.	Align engine cradle (M) on master gear platform (N).Master gear platform - Engine Cradle support - Engine
54.	Install fixings (M1).

Care Point:

Align cradle underneath engine and transmission with supports (M1 - M3).

55.

Locate cradle underneath vehicle.

Care Point:

Take care to correctly position the cradle and slowly lower engine / transmission (E1 - E3).

56.

Lower engine / transmission to cradle.

57.

Locate fixing bolt through the hole into the frame (M2).

58.

Undo the centre nut (46) on transmission mount.(M22) 40 Nm

Care Point:

Use 2 x 24 inch ½ drive extension with 21mm sockets to remove bolt.

Care Point:

Take care when removing due to torque value / locking compound on thread.

59.

Remove transmission mount bolt (47).(M14x123) 135 Nm

60.

Remove engine frame bolts (48).(M10x30) 75 Nm

61.

Remove engine frame bolts (49).(M12x110) 132 Nm

Care Point:

Care must be taken to make sure all components are free and clear of the structure when raising the vehicle.

62.

Slowly raise vehicle a bit away from the engine.

63.	Detach clamp (51).
64.	Detach front CCV breather hose (50) from oil tank.
65.	Release jubilee clip and detach MAF tube duct to turbo-charger.
66.	Slowly raise vehicle a away from the engine.

Care Point:

When moving an engine from the engine cradle after transmission removal to a storage method (wooden pallet/chocks) (W), make sure that there is no contact (arrows) between the storage method and the turbo drain pipes (52). These pipes are not to be subjected to any load during storage (W). This also applies to engines waiting to installed on to the engine cradle.

67.

Once vehicle is clear of engine, remove engine with cradle.

Install engine

Care Point:

If replacing the engine, make sure that the original and new engine serial numbers are documented on the work package.

If a new engine is being fitted, it is recommended that the oil tank and related hoses are removed from the vehicle and are cleaned / flushed thoroughly before the installation of the engine is carried out. There should be no visible traces of debris once the flushing process is completed. This will prevent any contamination being transferred to the new power unit.

Care Point:

Care must be taken to make sure all components are free and clear of the structure when lowering the vehicle.

Slowly lower vehicle onto engine.

Care Point:

Replace O-rings.

Care Point:

Check all hoses for suitable clearances.

Care Point:

Make sure electrical connectors are fitted correctly.

Care Point:

If NVH pad/s are damaged, check around area for debris and replace pad/s.

Install components in reverse order - excluding rear floors, wheel arch liners and wheels.

Read out and clear error memory.

Connect McLaren Diagnostic System, proceed to Diagnostic toolbox within Engine Control Unit (ECU).

Access Sequences section.

Carry out Misfire adaptions routine.

Care Point:

The procedure below must be claimed separately if you make a warranty claim.

Suspension bleed procedure.DA-RM-04B003-00-001 - Fill/Bleed fluid - Suspension system

Start engine and leave running for 5 minutes for self learning to take place.

Check engine for leaks.

10.

Install rear floors, wheel arch liners and wheels.

11.

Connect McLaren Diagnostic System, proceed to Diagnostic toolbox within Engine Control Unit (ECU).

12.

Access Actual Values section.

Care Point:

Value should read between 1 and 4.

13.

Check Camshaft actual values.

V. 1.11

Note