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-05F001-01-003 - Remove/Install NVH - Front Cover
55.	DA-RM-05F001-01-026 - Remove/Install fuel rail
56.	DA-RM-05F001-01-031 - Remove/Install crank case ventilation (CCV) breather system
57.	DA-RM-05F001-01-028 - Remove/Install Intake manifold assembly
58.	Care Point: Remove both sides. DA-RM-05F001-01-015 - Remove/Install sensor - Cam phaser
59.	Care Point: Remove both sides. DA-RM-05F001-01-023 - Remove/Install Assembly - Turbocharger
60.	Care Point: Remove both sides. DA-RM-05F001-01-035 - Remove/Install exhaust manifold
61.	DA-RM-05F001-01-034 - Remove/Install Ignition coil
62.	DA-RM-05F001-01-008 - Remove/Install camshaft cover - Left
63.	DA-RM-05F001-01-009 - Remove/Install camshaft cover - Right
64.	DA-RM-05F001-01-033- Remove/Install spark plug
65.	DA-RM-05F001-01-002 - Remove/Install front cover

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 chain drive kit - Camshaft

Care Point:

Block oil return galleries to prevent contamination.

Cover the area around the cylinder head to prevent contamination (arrows).

Care Point:

Make sure the engine always rotates in the correct direction of rotation (arrow).

Turn crank in the engine's direction of rotation.

Rotate crank to position with machined flat are on top (arrow). Additional flats are on both sides.

Remove timing pin plug (A). 20 Nm

Push down the transmission floor crossbeam (B) in direction ©).

Care Point:

Two technicians will be needed.

Care Point:

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

Insert crankshaft locking tool (F) in direction (G). Camshaft locking/timing - Engine

Remove bolts (H) and remove heatshield. (M6x16) 10 Nm

Care Point:

Before disassembling the engine the locking pins in the VCT phasers need to be checked for a positive connection to prevent incorrect valve timing when the engine is re-assembled.

Using flat edge of cam shaft (I), attempt to rotate each camshaft in the opposite direction of its rotation (maximum 20 degrees). If camshaft rotates independently from VCT phaser, the locking pin in the VCT phaser has failed and requires replacement.

Chain driven VCT/Camshaft - Rotate anti-clockwise.

None chain driven VCT/Camshaft - Rotate clockwise.

Care Point:

Two technicians will be needed.

Care Point:

Fit camshaft tool (L) rotate crankshaft (J) in clockwise direction (K).

Apply camshaft special tool (L) on the machined flat (M) on the camshaft (N). Camshaft locking/timing - Engine

10.

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

11.

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

12.	Remove dowel screws (1). (M8) 27 Nm
13.	Remove chain tensioner blade (2).

14.	Remove dowel screws (3). (M8) 27 Nm
15.	Remove chain guide (4).

16.	Remove bolt (5) from compound gear (6). (M12x50) 110 Nm
17.	Remove pedestal (7).
18.	Remove compound gear (6).
19.	Remove timing chain right.

20.	Remove dowel screws (8). (M8) 27 Nm
21.	Remove chain guide (9).

22.	Remove dowel screws (10). (M8) 27 Nm
23.	Remove chain tensioner blade (11).
24.	Remove timing chain left.

Install chain drive kit - Camshaft

Care Point:

Install chain through head opening and hang from left bank exhaust cam.

Care Point:

All M8 dowel screws are single use only. These bolts will have pre-encapsulated loctite on them. If this is not on the replacement bolt, apply Loctite 270 to the bolt thread.

Install timing chain left.

2.	Install cam phaser exhaust left (12).
3.	Hand start bolt (13).

Care Point:

Install chain through head opening and hang from right bank inlet cam.

Install timing chain right.

Install cam phaser inlet right (14).

Hand start bolt (15).

7.	Install chain tensioner blade (11).
8.	Install dowel screws (10). (M8) 27 Nm Loctite 270

Install compound gear (6) to chain LH.

10.	Apply the special tool (L). Compound Gear Alignment - Engine
11.	Tighten special tool (L).
12.	Install chain RH to compound gear (6).

13.	Install chain guide (9).
14.	Install dowel screws (8). (M8) 27 Nm Loctite 270

15.

Remove the special tool (L).

16.

Install pedestal (7).

17.

Hand start bolt (5) from compound gear (6).

Care Point:

Applying downward pressure to the compound gear during installation will set the backlash.

18.

Tighten bolt (5). (M12x50) 110 Nm

19.	Install chain guide (4).
20.	Install dowel screws (3). (M8) 27 Nm Loctite 270

21.

Install chain tensioner blade (2).

22.

Install dowel screws (1). (M8) 27 Nm Loctite 270

Care Point:

Make sure pedestal is fully engaged in recess in crankcase.

23.

Install timing chains left and right in reverse order.

Care Point:

After installing chain tensioners tighten bolts cam phaser.

24.

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

25.

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

Care Point:

Remove all special tools for locking the camshafts and the crankshaft.

26.

Check engine timing.

27.

Rotate crankshaft through two revolutions.

Care Point:

Two technicians will be needed.

Care Point:

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

28.

Check position of crankshaft with the crankshaft locking tool (F). Crankshaft Seal Front Expander - Engine

Care Point:

Before disassembling the engine the locking pins in the VCT phasers need to be checked for a positive connection to prevent incorrect valve timing when the engine is re-assembled.

29.

Chain driven VCT/Camshaft - Rotate anti-clockwise.

None chain driven VCT/Camshaft - Rotate clockwise.

Care Point:

Two technicians will be needed.

Care Point:

Fit camshaft tool (L) rotate crankshaft (J) in clockwise direction (K).

30.

Check and secure position of the camshaft (N) with the camshaft locking device special tool (L). Camshaft locking/timing - Engine

31.

Checking engine timing. DA-RM-05F001-00-001 - Check engine timing

32.

Remove all special tools to unlock the camshafts and the crankshaft.

Care Point:

Replace O-ring.

33.

Install timing pin plug (A) 20 Nm with new O-ring.

34.

Install spark plugs.

Care Point:

Clean surfaces from all detached engine parts.

Care Point:

Renew front cover.

35.

Install components in reverse order.

36.

Read out and clear error memory.

37.

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

38.

Check engine for leaks.

V. 1.11

Note