E Gear LAMBORGHINI GALLARDO 2009 Workshop Manual
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W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
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% $ V V H P E O L Q J W K H J H D U V H O H F W L R Q F D E O H V 1. Position the lever and gear selection cable assembly.
2. Tighten the three screws ( $ ) L J ) securing the gear selection cable support bracket to the gearbox.
Secure the gear selection cable, release the safety springs ( % ) L J D Q G S R V L W L R Q W K H F R U U H V S R Q G L Q J F O L S V ¿ [ L Q J
them to the bracket ( & ) L J ).
4. 7 L J K W H Q W K H V F U H Z V V H F X U L Q J W K H F O D P S V ¿ [ L Q J W K H J H D U V H O H F W L R Q F D E O H V ' ) L J ) to the chassis and engine.
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
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W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
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5. Position the snap rings ( ( ) L J ) securing the selection cables to the gearbox lever.
Position the clips ( ) ) L J ) securing the gear selection cable to the gearbox shift lever device.
7. Tighten the six screws ( * ) L J ) securing the cover of the gearbox shift lever device.
2 Q F H J H D U V H O H F W L R Q F D E O H D V V H P E O \ L V F R P S O H W H D G M X V W W K H J H D U E R [
• $ V V H P E O H W K H D L U ¿ O W H U .
• Assemble the engine bay aesthetic panels .
• Assemble the propeller shaft .
• $ V V H P E O H W K H F H Q W U H D Q G U H D U Y H K L F O H À R R U V .
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® Automobili Lamborghini S.p.A.
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B) Disassembling the accelerator pedal cluster
$ ' L V D V V H P E O L Q J W K H E U D N H F O X W F K S H G D O F O X V W H U P D Q X D O J H D U E R [ Y H U V L R Q R Q O \ 3 U H O L P L Q D U \ R S H U D W L R Q V •
Disassemble the instrument cluster grille .
• Disassemble the instrument cluster .
• Disassemble the driver side dashboard assembly .
• Disassemble the brake booster reservoir .
Disassembly
1. Detach the pedal cluster support ( A-Fig.1) by unscrewing the 4 mounting screws ( B-Fig.1).
2. Remove the pedal cluster.
To disassemble the pedal from the pedal cluster:
3.Detach the spring ( C-Fig.2) connecting the pedal cluster support to the pedal (1 spring for automatic gearboxes,
2 springs for manual gearboxes).
4. Remove the pin ( D-Fig.2) and secure the journal ( E-Fig.2) between the pedal cluster and the connecting rod
( F-Fig.2 ).
5. Unscrew the screw ( G-Fig.1) securing the pedal cluster shaft.
Remove the pedal ( H-Fig.1) (2 pedals for manual gearboxes).
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® Automobili Lamborghini S.p.A.
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/ D P E R U J K L Q L 6 S $ E D V H G R Q F R S \ U L J K W O D Z $ O O R I W K H 3 ' ) F K D S W H U V L Q W K H : ( % Z R U N V K R S P D Q X D O V G H V F U L E H G E H O R Z D U H E D V H G R Q L Q I R U P D W L R Q D Y D L O D E O H D W W K H W L P H R I S X E O L F D W L R Q 7 K H F R P S D Q \ U H V H U Y H V
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B) Assembling the accelerator pedal cluster
$ $ V V H P E O L Q J W K H E U D N H F O X W F K S H G D O F O X V W H U P D Q X D O J H D U E R [ Y H U V L R Q R Q O \
To assemble the pedal on the pedal cluster:
1.
Position the pedal ( A-Fig.1) (1 pedal for automatic gearboxes, 2 for manual gearboxes) and insert the shaft.
2. Secure the shaft using the screw ( B-Fig.2).
3. Secure the connecting rod ( C-Fig.2) to the pedal using the journal ( D-Fig.2) with the mounting pin ( E-Fig.2).
4. Connect the pedal to the support using the spring ( F-Fig.2) (1 spring for E-Gear cars, 2 for manual gearbox
cars).
To assemble the entire pedal cluster on the car:
5. Secure the pedal cluster support ( G-Fig.1 W R W K H F D U À R R U X V L Q J W K H V F U H Z V H-Fig.1).
6 F U H Z D W W D F K P H Q W W L J K W H Q L Q J W R U T X H E
6. Run a brake pedal test .
• Assemble the brake booster reservoir .
• Assemble the driver side dashboard assembly .
• Assemble the instrument cluster .
• Assemble the instrument cluster grille .
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W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
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% $ V V H P E O L Q J W K H W X Q Q H O R U Q D P H Q W 1. Connect the 3 connections ( $ ) L J ) to the respective ports on the tunnel ornament ( % ) L J ) (the manual
gearbox version has 2 connections).
2. Position the ornament so that the slot ( & ) L J ) at the front enters the guide.
3. Press the ornament in so that the 2 clips ( ' ) L J ) enter the couplings.
4. Secure the gearlever block to the ornament using the 2 screws (manual gearbox version only).
5. Tighten the gearlever knob (manual gearbox version only).
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1.
Position the driver side lower dashboard assembly ( $ ) L J ) and secure it at the top using the 2 stud bolts
( % ) L J ).
2. Connect the connector ( & ) L J ) of the reverse gear button (E-GEAR version only).
3. Tighten the 3 mounting screws ( ' ) L J ).
• Assemble the instrument cluster 3 R L Q W 1 .
• Assemble the instrument cluster grille 3 R L Q W 0 .
• Assemble the left side cover 3 R L Q W 3 .
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5. Unscrew the nut ( ) ) L J ) securing the positive rear battery cable to the alternator ( * ) L J ).
6 . Disconnect the 3 clamps ( + ) L J ) securing the cable on the gearbox assembly ( , ) L J ).
7. Disconnect the connector ( / ) L J ) from the starter ( 1 ) L J ).
8. Unscrew the nut ( 0 ) L J ) securing the rear positive cable to the starter ( 1 ) L J )
Page 1349 of 1659
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% $ V V H P E O L Q J W K H S R V L W L Y H E D W W H U \ F D E O H U H D U S D U W $ V V H P E O L Q J W K H S R V L W L Y H E D W W H U \ F D E O H U H D U S D U W1.
Tighten the nut ( B-Fig.7) securing the rear positive cable to the starter ( C-Fig.7).
2. Connect the connector ( A-Fig.7) to the starter ( C-Fig.7).
3 . Insert 3 clamps ( ' ) L J 8) to secure the cable to the wiring harness on the gearbox assembly ( ( ) L J 8).
4 . Connect the positive rear battery cable to the alternator ( ) ) L J 9) and tighten the nut ( * ) L J 9).
Page 1354 of 1659
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1.200 A Maxi fuse box 30
2. 50 A A/C Fan – Seat Heating 30
3. 80 A Water Radiator Fans 30
4. 50 A Key, ILM(Lights), +75 30
5. 6. 7. 50 A Main fuse box 30
8. 60 A ESP 30
9. 100 A Engine/Gearbox 30
10. - Power windows, seats, lifting 30
Page 1357 of 1659
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® Automobili Lamborghini S.p.A. 7 K H L Q I R U P D W L R Q D Q G S U R F H G X U H V S X E O L V K H G E H O R Z D U H V W U L F W O \ F R Q ¿ G H Q W L D O D Q G H [ F O X V L Y H O \ I R U W K H / D P E R U J K L Q L ' H D O H U 1 H W Z R U N D Q G $ X W K R U L ] H G 6 H U Y L F H 3 R L Q W V $ O O F R S \ U L J K W V D U H S U R S H U W \ R I $ X W R P R E L O L
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W K H U L J K W W R P D N H X S G D W H V D Q G P R G L ¿ F D W L R Q V 7 K H I R O O R Z L Q J D U H S U R K L E L W H G U H S U L Q W L Q J U H S U R G X F W L R Q I R U Z D U G L Q J W R X Q D X W K R U L ] H G S H R S O H D Q G R U W K L U G S D U W L H V D Q G W U D Q V O D W L R Q L Q F O X G L Q J S D U W L D O Z L W K R X W
Z U L W W H Q D X W K R U L ] D W L R Q I U R P $ X W R P R E L O L / D P E R U J K L Q L 6 S $
5 ( / $ < 6 8 3 3 2 5 7
5 ( / $ < 6
Pos. Base Colour Code 3 5 1 U
ID Number ' H V F U L S W L R Q
1.
Blue 8K0 951 253 643 Main relay
2. Gray 8K0 951 253 643 Secondary air pump relay 2
3. Purple 8D0 951 253 A 373 +50_1 relay
4. Red 8D0 951 253 A 373 +50_2 relay
5. 6. Orange 8K0 951 253 643 Secondary air pump relay 1
7. Green 8K0 951 253 643 Engine relay
8. White 357 927 843 A +G1E 179 E-Gear (SCAM) oil pump
9.
0 $ ; , ) 8 6 (
Pos. Fuse carrier colour
Value PR-Nr. ' H V F U L S W L R Q
Power
ABlack
50 A Secondary air pump 1 30
B Brown 40 A Fuel pump supply 87 HR
C D Red 50 A Secondary air pump 2 30
E