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
53.	DA-RM-05F001-01-001 - Remove/Install engine
54.	DA-RM-05E001-01-001 - Remove/Install heatshield - Exhaust manifold
55.	DA-RM-05F001-01-008 - Remove/Install camshaft cover - Left
56.	DA-RM-05F001-01-009 - Remove/Install camshaft cover - Right
57.	DA-RM-05F001-01-002 - Remove/Install front cover
58.	DA-RM-05F003-02-002 - Remove/Install hose - Turbo charger - Oil return
59.	DA-RM-05F001-01-023 - Remove/Install Assembly - Turbocharger
60.	DA-RM-05F001-01-035 - Remove/Install exhaust manifold
61.	DA-RM-05F001-01-011 - Remove/Install cam phaser - Left
62.	DA-RM-05F001-01-012 - Remove/Install cam phaser - Right

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 cylinder head

Care Point:

Graphics may show the installation / removal of one side. The installation / removal of the other side has to be carried out accordingly.

For removal of one cylinder head, only carry out pre-work for the relevant side.

Care Point:

Once engine has been removed from vehicle, install crankshaft locking tool.

Care Point:

If only changing the head gasket, leave turbo charger and exhaust manifold and remove these complete with the cylinder head.

Remove vee link harnesses.

Remove secondary air injection pipework.

Remove cam cover heatshield.

Care Point:

Block oil return galleries to prevent contamination.

Tape over (arrows) inlet channels.

Tape over oil galleries (arrows).

Remove dowel bolt (1) from chain guide left hand side (2). (M8) 27 Nm

Remove dowel bolt (3) from chain guide right hand side (4). (M8) 27 Nm

Care Point:

Remove front cap (A) first.

Care Point:

Remove bearing cap (B) once all other caps are removed. Release bolts (5) of the bearing caps (B) gradually to avoid bracing of the camshafts.

Remove bolts (5). (M6x35) 10 Nm

Care Point:

Bearing caps (6) are numbered from 1 to 8.

Remove bearing caps (6).

Care Point:

Remove front cap (D) first.

Care Point:

Remove bearing cap (E) once all other caps are removed. Release bolts (7) of the bearing caps (E) gradually to avoid bracing of the camshafts.

10.

Remove bolts (7). (M6x35) 10 Nm

Care Point:

Bearing caps (8) are numbered from 9 to 16.

11.

Remove bearing caps (8).

12.	Remove inlet camshaft (9).
13.	Remove exhaust camshaft (10).

Care Point:

Possibility of shims falling off the top of the valves. Remove shims and layout on bench with markers for the respective valve they were removed from.

14.

Remove bolts (11) in front of the cylinder head right hand side. (M6x20) 10 Nm

15.

Remove bolts (12) in front of the cylinder head left hand side. (M6x20) 10 Nm

16.

Remove caps from rear cylinder head bolts (7, 8).

Care Point:

Cylinder head bolts are single use only, dispose of once removed.

17.

Loosen cylinder head bolts in reverse order (10-1).

18.

Remove cylinder head bolts (10-1).

19.

Remove cylinder head.

Install cylinder head

Care Point:

The cylinder head bolt threads in the engine block must be clean before you install the cylinder head.

Care Point:

Do not let degreaser go into the coolant or oil ways.

Use degreaser and a brush to clean the cylinder head bolt threads in the engine block. Use compressed air to dry and remove remaining debris.

Care Point:

If fitting a new cylinder head, make sure that all reusable parts are transferred from the original head on to the new head i.e. exhaust manifold heatshield. Fit cylinder head heatshield after engine timing has been carried out.

Thoroughly clean sealing surface of cylinder head and engine block.

Check sealing surface (13) for evenness.

Care Point:

The overall flatness tolerance is 0.08 mm on the cylinder head, i.e. when a straight edge is placed over the head there should not be a gap of greater than 0.08 mm.

The second part is that over a 200 x 200mm area the flatness tolerance is more specific at 0.05 mm.

Measure tolerance with a straight edge ©) and feelers for cylinder head.

Clean tapped holes.

6.	Replace cylinder head gasket (15).
7.	Place cylinder head gasket on dowels (14).

Install tool (N).Cylinder head alignment - Engine

Care Point:

Install and torque cylinder head before shims are refitted. Make sure the correct shims are fitted to the correct valve.

Make sure all shims (16) are in place.

Care Point:

Take care not to damage the cylinder head gasket.

10.

Locate cylinder head onto engine block.

11.

Secure cylinder head with cylinder head bolts.

12.

Remove screw pins (N).

Care Point:

Follow the sequence to tighten the cylinder head bolts (1-10).

Care Point:

Lubricate threads only with engine oil .

Bolt heads and washer must be dry!

Care Point:

Make sure new bolts from gasket kit are used. Do not attempt to re-use old bolts.

Care Point:

Remove screw pins (N).

13.

Position cylinder head bolts.

14.

Tighten cylinder head bolts using torque sequence above (1-10), in the following stage order.

Stage 1 - (M12x145) 30 Nm

Stage 2 - (M12x145) 45 Nm

Stage 3 - (M12x145) 45 Nm then apply a 135° turn

Care Point:

Inspect caps, replace if damaged or can be removed easily.

15.

Install caps to rear cylinder head bolts (7, 8).

16.

Install bolts (12) in front of the cylinder head left hand side.(M6x20) 10 Nm

17.

Install bolts (11) in front of the cylinder head right hand side.(M6x20) 10 Nm

Care Point:

Turn camshafts (9, 10) in a position where camshaft can be turned least.

Care Point:

Position in reference to the 3rd and 4th cam lobe.

Place in 1 o'clock position on RH Bank.

Place in 11 o'clock position on LH Bank.

Oil journals, lobes and fingers before installation.

18.

Install exhaust camshaft (10).

Care Point:

Position in reference to the 3rd and 4th cam lobe.

Place in 11 o'clock position on RH Bank.

Place in 1 o'clock position on LH Bank.

Oil journals, lobes and fingers before installation.

19.

Install inlet camshaft (9).

Care Point:

All bearing caps must have arrow towards front of engine.

Care Point:

Bearing caps (8) are numbered from 9 to 16.

Care Point:

Apply small quantity of hypoid oil to tops of bearing caps and across the top of the camshaft before installation of the caps (8).

20.

Install bearing caps (8).

Care Point:

Install front cap (D) first.

Care Point:

First install bolts M6 (7) of the bearing caps (E) gradually to avoid bracing of the camshafts, then the remaining bolts (7).

21.

Install bolts (7).

Care Point:

Tighten caps in following sequence - 9, 13, 14, 10, 11, 15, 16, 12

22.

Tighten bolts (7). (M6x35) 10 Nm

Care Point:

All bearing caps must have arrow towards front of engine.

Care Point:

Bearing caps (6) are numbered from 1 to 8.

Care Point:

Apply small quantity of hypoid oil to tops of bearing caps (6).

23.

Install bearing caps (6).

Care Point:

First install bolts M6 (5) of the bearing caps (A) gradually to avoid bracing of the camshafts, then the remaining bolts (5).

24.

Install bolts (5).

Care Point:

Tighten caps in following sequence - 5, 1, 2, 6, 7, 3, 4, 8.

25.

Tighten bolts (5). (M6x35) 10 Nm

26.

Turn camshafts to safe position (arrow).

Care Point:

Two technicians will be needed.

Care Point:

To fit crankshaft locking tool (F) rotate crankshaft (D) in clockwise direction (E).

27.

Check position of crankshaft with the crankshaft locking tool (F). Crankshaft Locking Pin - Engine

28.

Install the camshaft locking special tool (H). Camshaft locking/timing - Engine

29.

Install cam phasers left. DA-RM-05F001-01-011 - Remove/Install cam phaser - Left

30.

Install cam phasers right. DA-RM-05F001-01-012 - Remove/Install cam phaser - Right

31.

Carry out engine timing procedure. DA-RM-05F001-00-001 - Check engine timing

32.

Install components in reverse order.

33.

Read out and clear error memory.

Care Point:

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

34.

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

35.

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

36.

Check engine for leaks.

V. 1.10

Note