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.	DA-RM-05F001-01-015 - Remove/Install sensor - Cam phaser
59.	DA-RM-05F001-01-035 - Remove/Install exhaust manifold
60.	DA-RM-05F001-01-009 - Remove/Install camshaft cover - Right
61.	DA-RM-05F001-01-034 - Remove/Install Ignition coil

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 cam phaser - Right

Care Point:

Always replace the cam phaser bolts. Refer to the Spare Parts Catalogue (SPC) for part numbers.

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:

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

Insert crankshaft locking tool (F) in direction (G). Crankshaft Locking Pin - 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:

To 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 bolts (1). (M6x20) 10 Nm

Care Point:

Lever off the cylinder head front cover using the machined recess.

11.

Remove cylinder head front cover (2).

Care Point:

If a tension pin is not available, use a heat treated device with a diameter of 3 mm.

12.

Press back pin (arrow) of the chain adjuster (3).

13.

Insert tension pin (4) to secure it.

14.

Remove bolts (5). (M6x20) 10 Nm

Care Point:

Engine oil may escape when removing the chain adjuster.

15.

Remove chain adjuster (3).

Care Point:

If you hold up camshafts for removing bolts (8), make sure you do not damage retainer plate / rocker pivot (6) and cam cover seal face (7).

16.

Hold up camshafts. Use a spanner to react torque.

Care Point:

Avoid consumables falling between the engine and engine front cover. That may lead to engine damage.

Work with caution.

Install: Apply CMD - Extreme Pressure Lube to VCT bolts.

17.

Remove bolts (8). (M14x100) 10 Nm then release bolt by 360 degree turn

Care Point:

If replacement of cam phaser bolt only is required, do not continue with removal of phasers.

18.

Remove inlet cam phaser (9) with a puller.

19.

Remove exhaust cam phaser (10) with a puller.

Install cam phaser - Right

Care Point:

Always replace the cam phaser bolts. Refer to the Spare Parts Catalogue (SPC) for part numbers.

Care Point:

If a cam phaser has been removed for access only - The cam phaser must be replaced under the following conditions:

If sign of wear or damage is present on either the VCT bolt, or there is sign of wear or damage on the VCT bolt to Cam Phaser mounting face.

Clean all engine surfaces / components on area of assembly.

Care Point:

Make sure sleeves are fitted to the phaser before installation. Transfer sleeves from old phaser to the new phaser unless new sleeves have been provided.

Care Point:

Make sure tension pin has been removed.

Care Point:

Make sure a small amount of CMD - Extreme Pressure Lube is applied to the tapered face of the cam phaser bolt under head.

Do not apply oil or grease to the thread of the bolt under any circumstances.

Care Point:

Make sure the camshaft nose is clean and free from any oil or dirt before installing the cam phaser.

Care Point:

When installing the inlet cam phaser, use a 26 mm spanner on the hexagonal cast feature to react the torque.

Care Point:

Make sure Camshaft locking/timing - Engine is fitted.

Care Point:

Instructions below detail fitment of all four cam phaser.

Proceed to next step if current step does not relate to the pair of cam phaser removed.

Install cam phaser in the following order:

Install RH Inlet and / or LH Exhaust cam phaser to camshaft

Install timing chain to RH Inlet and / or LH Exhaust cam phaser

Care Point:

Make sure bolt is released by a 360 degree turn once torque is applied.

Torque phaser bolt/s to first stage. (M14x100) 10 Nm then release bolt by 360 degree turn

Install RH Exhaust and / or LH Inlet cam phaser to camshaft

Care Point:

Make sure bolt is released by a 360 degree turn once torque is applied.

Torque phaser bolt/s to first stage. (M14x100) 10 Nm then release bolt by 360 degree turn

Care Point:

Rotate clockwise. Do not use tool on chain sprocket, use on forward sprocket only.

Care Point:

Make sure 10 Nm is applied first to allow the sleeve to re-settle.

Use VCT Rotation tool to make sure chain is tight around RH Inlet cam phaser.

Torque phaser bolt to second stage. (M14x100) Return to 10 Nm then apply 50 Nm

Care Point:

Rotate clockwise. Do not use tool on chain sprocket, use on forward sprocket only.

Care Point:

Make sure 10 Nm is applied first to allow the sleeve to re-settle.

Use VCT Rotation tool to make sure chain is tight around LH Exhaust cam phaser.

Torque phaser bolt to second stage. (M14x100) Return to 10 Nm then apply 50 Nm

Torque LH Inlet phaser bolt to second stage. (M14x100) Return to 10 Nm then apply 50 Nm

10.

Torque RH Exhaust phaser bolt to second stage. (M14x100) Return to 10 Nm then apply 50 Nm

11.

Torque RH Inlet cam phaser to third stage. (M14x100) Return to 50 Nm then apply 100 degree turn

12.

Torque LH Exhaust cam phaser to third stage. (M14x100) Return to 50 Nm then apply 100 degree turn

13.

Torque LH Inlet cam phaser to third stage. (M14x100) Return to 50 Nm then apply 100 degree turn

14.

Torque RH Exhaust cam phaser to third stage. (M14x100) Return to 50 Nm then apply 100 degree turn

Care Point:

Check engine timing before continuing.

Following steps 8 - 12.

15.

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

Care Point:

Remove all old Three Bond 1217F-GM from the engine and cylinder head front cover and make sure area is grease free before installation.

16.

Apply sealing material (11) to cylinder head front cover (2), as shown in the diagram. Three Bond 1217F-GM

Care Point:

Once RTV has been applied, there is maximum operating time of 15 minutes before the RTV sets. If the cover is not fitted within this time, repeat step 4.

17.

Install cylinder head front cover RH (2).

18.

Install bolts (1). (M6x20) 10 Nm

Care Point:

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

19.

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

20.

Rotate crankshaft through two revolutions.

Care Point:

Two technicians will be needed.

Care Point:

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

21.

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

22.

Chain driven VCT/Camshaft - Rotate anti-clockwise.

None chain driven VCT/Camshaft - Rotate clockwise.

Care Point:

Two technicians will be needed.

Care Point:

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

23.

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

24.

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

Care Point:

Replace O-ring.

25.

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

Care Point:

Clean surfaces from all detached engine parts.

26.

Install components in reverse order.

27.

Check engine for leaks.

28.

Check oil level. DA-RM-05F003-00-002 - Check engine oil level

29.

Check cooling system.

30.

Read out and clear error memory.

V. 1.12

Note