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: Make sure EPB calipers are in service mode before disconnecting battery. DA-RM-07M003-00-001 - Disconnect/Connect Li-ion battery
5.	DA-RM-04L001-00-001 - Drain/Fill fluid - Coolant
6.	Care Point: Only drain transmission oil if replacing gearbox. DA-RM-05G001-00-001 - Drain/fill fluid - Transmission oil
7.	Care Point: Remove both sides. DA-RM-04B005-01-001 - Remove/Install wheel - Rear
8.	Care Point: Remove both sides. DA-RM-03A076-02-001 - Remove/Install wheel arch liner - Rear
9.	DA-RM-01A004-02-001 - Remove/Install floor panel - Engine
10.	Care Point: Remove both sides. DA-RM-03A075-05-002 - Remove/Install floor panel - Rear extension
11.	DA-RM-03A075-05-001 - Remove/Install floor panel - Diffuser
12.	DA-RM-01A004-02-002 - Remove/Install floor panel - Transmission
13.	DA-RM-01A003-01-002 - Remove/Install crossbeam - Transmission floor
14.	DA-RM-02A051-08-002 - Remove/Install panel - Rear deck vent
15.	DA-RM-02A051-08-001 - Remove/Install panel - Service Cover
16.	DA-RM-02A051-08-003 - Remove/Install panel - Engine bay cover
17.	DA-RM-02A053-03-001 - Remove/Install panel - Airbrake
18.	Care Point: Remove both sides. DA-RM-02A051-03-004 - Remove/Install panel - Side duct finisher
19.	Care Point: Remove both sides. DA-RM-02A051-03-003 - Remove/Install panel - Dirty air duct
20.	Care Point: Remove both sides. DA-RM-02A051-03-002 - Remove/Install bodyside - Lower
21.	Care Point: Remove both sides. DA-RM-02A051-03-005 - Remove/Install panel - Aero bridge
22.	Care Point: Remove both sides. DA-RM-02A051-03-001 - Remove/Install bodyside - Upper - Left
23.	DA-RM-03A071-10-001 - Remove/Install bumper assembly - Rear
24.	DA-RM-05E001-02-002 - Remove/Install heatshield - Muffler - Upper
25.	DA-RM-05H001-02-001 - Remove/Install muffler
26.	DA-RM-05E001-02-003 - Remove/Install heatshield - Muffler - Lower
27.	DA-RM-05E001-02-004 - Remove/Install heatshield - Airguide
28.	DA-RM-02A051-08-004 - Remove/Install heatshield - Deck vent rear
29.	DA-RM-05F002-03-001 - Remove/Install water charge air cooler (WCAC)
30.	Care Point: Remove both sides. DA-RM-05H001-01-001 - Remove/Install catalytic converter and link pipe assembly - Left
31.	Care Point: Remove both sides. DA-RM-05F002-01-004 Remove/Install duct - airbox to clean air duct
32.	DA-RM-05F001-03-001 - Remove/Install pump - Secondary air
33.	DA-RM-01A003-02-002 - Remove/Install bumper beam - Rear
34.	Care Point: Remove both sides. DA-RM-04C002-03-001 - Remove/Install brake disc cooling duct - Rear
35.	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
36.	Care Point: Remove both sides. DA-RM-04C004-01-001 - Remove/Install brake caliper - Parking
37.	Care Point: Remove both sides. DA-RM-04C002-01-001 - Remove/Install brake disc - Rear
38.	DA-RM-05F005-01-001 - Remove/Install starter motor

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!

Risk of injury and poisoning working with hydraulic fluid!

Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. When disengaging hydraulic lines without depressurising the system, dangerous skin or eye injuries can occur due to the very high pressures (in excess of 200 bar). If hydraulic fluid, particularly central hydraulic fluid (especially harmful), comes into contact with unprotected skin, this can cause damage to the skin.

If hydraulic fluid is swallowed, this can lead to poisoning symptoms such as headache, dizziness, nausea, vomiting, diarrhoea, cramps and unconsciousness.

Wear protective gloves, protective clothing and eye protection.

•	Depressurise and drain the system if necessary when commencing work on hydraulic systems.
•	Never put hydraulic fluid into beverage containers.
•	Ensure sufficient ventilation, especially in the case of central hydraulic fluid.
•	Ensure that only authorised persons have access to hydraulic fluid.
•	Immediately seal disconnected leads and hoses and the connections to the assembly with blind plugs.

WARNING!

Risk of injury and poisoning working with hydraulic fluid!

If hydraulic fluid is swallowed, this can lead to poisoning symptoms such as headache, dizziness, nausea, vomiting, diarrhoea, cramps and unconsciousness.

Wear protective gloves, protective clothing and eye protection.

•	Depressurise and drain the system if necessary when commencing work on hydraulic systems.
•	Never put hydraulic fluid into beverage containers.
•	Ensure sufficient ventilation, especially in the case of central hydraulic fluid.
•	Ensure that only authorised persons have access to hydraulic fluid.
•	Immediately seal disconnected leads and hoses and the connections to the assembly with blind plugs.

Remove dual clutch transmission (DCT)

Care Point:

Complete steps on both sides of vehicle where required.

Care Point:

Using a suitable tray catch the fluid where required.

Remove bolts (1). (M5x35) 5 Nm

Disconnect hose.

Remove bolts (2). (M5x30) 5 Nm

Disconnect hoses.

5.	Release lock and detach displacement sensor link rod (3) from lower wishbone.
6.	Disconnect wheel speed sensor (4).
7.	Disconnect rear suspension accelerometer (5).
8.	Disconnect the three actuator electrical connectors (6).
9.	Detach EPB harness from lower wishbone.

10.

Remove drive shaft nut (7). 260 Nm

11.

Disconnect track rod (8). (M14) 90 Nm

12.

Remove damper bolts (9). (M10x40) 57 Nm

Care Point:

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

13.

Remove upper wishbone bolts (10). (M10x30) 57 Nm

14.

Remove lower wishbone bolts (11). (M10x30) 57 Nm

Care Point:

Suspension removed as an assembly.

15.

Remove suspension assembly.

16.

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

Care Point:

Counter hold union when disconnecting hoses.

17.

Disconnect airbrake hoses (12) from airbrake mechanism. 20 Nm

Care Point:

Left hand hose has a dot mark above union.

18.

Disconnect airbrake hoses (13) from transmission. 22 Nm

19.	Remove clamp bolt (14). (M6x16) 8 Nm
20.	Remove suspension hoses (15) and airbrake hose / valve block assembly (16) from vehicle.

21.

Disconnect electrical connectors (17) and lay aside harness onto transmission.

22.

Disconnect electrical connectors (18) and lay aside harness onto transmission.

23.	Remove bolt (19) and disconnect clutch cooler pipe. (M6x16) 8 Nm
24.	Release clamp (20) and disconnect transmission cooler pipe.

25.	Remove bracket bolt (21). (M5x10) 8 Nm
26.	Remove bolt (22) and disconnect pipe from engine. (M6x16) 8 Nm

27.	Remove bolts (23). (M6x16) 8 Nm
28.	Disconnect and remove transmission cooler pipes from vehicle.
29.	Remove ground bolt (24). (M8x16) 13 Nm

Care Point:

Not all fixings are shown in graphic. Make sure all nuts and bolts have been removed before attempting to separate engine and transmission.

30.

Remove lower nut (25). (M10) 50 Nm

31.

Remove lower bolts (26). (M10x120) 50 Nm

32.	Install engine cradle (T1) on to mastergear platform (T2). Cradle support - Engine Master gear platform - Engine
33.	Install engine cradle fixings (T3).

Care Point:

Align engine cradle underneath engine and transmission with supports (T4) extended.

34.

Locate engine cradle underneath vehicle.

Care Point:

Make sure supports (T4) are correctly positioned in areas shown (A1).

35.

Lower transmission to cradle.

36.

Insert suitable wedge between engine (27) and frame (28) in area shown (A2).

37.

Undo adjuster screw (29). (M22) 40 Nm

Care Point:

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

Care Point:

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

Care Point:

When Installing , apply torque at nut.

38.

Remove nut (30). (M14) 135 Nm

39.

Remove transmission mount bolt (31).

40.

Strap transmission to cradle (32).

Care Point:

Not all fixings are shown in graphic. Make sure all nuts and bolts have been removed before attempting to separate engine and transmission.

41.

Remove remaining transmission fixings (33). (M10) 50 Nm

42.

Separate transmission from engine.

Care Point:

Make sure all components are free and clear of the structure when raising the vehicle.

43.

Slowly raise vehicle away from transmission.

44.

When vehicle is clear of transmission, remove transmission on mastergear platform (T2). Master gear platform - Engine

Install dual clutch transmission (DCT)

Make sure input shaft and driveline damper splines are free from grease, oil or dirt.

Care Point:

Make sure grease does not exceed driveline damper splines.

Care Point:

Do not apply grease to input shaft.

Apply Clutch grease to driveline damper splines.

Care Point:

Make sure grease is not present on lead-in chamfer or rear face of driveline damper.

Do not use the same cleaning material for lead-in chamfer and rear face that is used to clean excess grease in splines.

Wipe away excess grease, leaving grease inside spline grooves only.

Make sure area is clean and free from dirt and debris to avoid contamination.

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 transmission.

Care Point:

Replace O-rings.

Install components in reverse order, excluding rear floors.

Connect McLaren Diagnostic System, proceed to Diagnostic Toolbox within Transmission Control Unit (TCU).

Access Sequences section.

Care Point:

Safety Critical! Make sure no technicians are working at the rear of vehicle whilst calibration sequences are in operation.

Care Point:

Carry out steps 9 and 10 only if the dual clutch transmission has been replaced.

Carry out Transmission Replacement Reset sequence.

10.

Carry out Transmission Calibration sequence.

Care Point:

Air Brake Bleed sequence also completes the Calibration sequence. It is not required to carry out both sequences separately.

11.

Carry out Air Brake Bleed sequence.

12.

Proceed to Diagnostic Toolbox within Engine Control Module (ECM).

13.

Access Sequences section.

14.

Carry out Misfire Adaptions sequence.

Care Point:

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

15.

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

16.

Check transmission, airbrake and suspension for leaks.

17.

Install rear floors.

18.

Carry out diagnostic check and clear any fault codes.

V. 2.11

Note