E Gear LAMBORGHINI GALLARDO 2009 Service Manual
Page 203 of 1659
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Fig.6
G
H
Fig.7
I
® 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
/ 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
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 $
7. Free the axle shafts from the gearbox following this procedure
• insert 5 nuts ( G-Fig.6 L Q W R W K H Z K H H O G L V F W R N H H S L W V W H D G \ Z K L O H W K H D [ O H V K D I W ¿ [ L Q J V F U H Z V D U H E H L Q J
removed;
' R Q R W W L J K W H Q W K H Q X W V F R P S O H W H O \ E X W M X V W D V P X F K D V Q H F H V V D U \ W R O R F N L W .
• X Q V F U H Z W K H D [ O H V K D I W ¿ [ L Q J E R O W V H-Fig.6) while keeping the disc steady with the help of the nuts
mounted on it;
• perform the operations for both axle shafts.
' R Q R W X V H R W K H U W R R O V R U S U R F H G X U H V I R U O R F N L Q J W K H G L V F V W K H G L V F V F R X O G E H G D P D J H G
8. 8 Q V F U H Z W K H ¿ [ L Q J E R O W R I W K H J U R X Q G H \ H I-Fig.7) of the starter and remove the ground cable.
Page 204 of 1659
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LL
Fig.8
Fig.9
b
a
a
® 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
/ 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
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 $
9. 5 H P R Y H W K H W Z R J H D U E R [ V X S S R U W ¿ [ L Q J E R O W V (L-Fig.8 ).
Disassembling the manual gearbox involves releasing the gear selection cables ( a-Fig.9 ) and the clamp
( b-Fig.9 ).
Page 212 of 1659
13
L714 01 00 03
Fig.17
C
F
' (
(
A
%
® 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
/ 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
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 $
Remove the engine wiring harness. •Disassemble the bench (086803).
• Disassemble the right side member cover (086803).
• Disassemble the right B pillar cover (086803).
21. Disconnect the E-gear control unit connectors ( A-Fig.17) and loosen the corresponding earth ( % ) L J ). Only
for vehicles equipped with an E-gear system.
22. Disconnect the connections of the 4 relays ( C-Fig.17) connected to the main electrical system.
23. Detach the 2 fuse blocks ( ' ) L J ) from the corresponding support.
24. Loosen the 2 screws ( ( ) L J ) securing the relay support ( F-Fig.17) to the chassis.
25 . Disconnect the 7 relays on the support ( F-Fig.17).
1- Blue 643 main relay.
2- Gray 643 secondary air pump relay.
3- Purple 373 +50 1 relay.
4- Red 373 +50 2 relay.
5- Orange 643 secondary air pump 1 relay.
6- Green 643 engine relay.
7- White 179 E-gear pump relay (only on vehicles equipped with an E-gear system).
8- Blank.
9- Blank.
26. Disconnect the 3 fuses on the relay support ( F-Fig.17).
A- Black - 50A secondary air pump 1.
B- Brown - 40A fuel pump supply.
C- Blank.
D- Red - 50 A secondary air pump 2.
Page 220 of 1659
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Fig.2
A
Fig.3
® 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
/ 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
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. $ V V H P E O H W K H F O X W F K À \ Z K H H O (014105).
6. Install the gearbox (030105) R Q W K H H Q J L Q H X V L Q J D Q D S S U R S U L D W H O L I W L Q J G H Y L F H Fig.2)
$ V V H P E O L Q J W K H H Q J L Q H L Q W K H Y H K L F O H 1. 6 H F X U H W K H H Q J L Q H W R W K H O L I W L Q J G H Y L F H A-Fig.3 E \ K R R N L Q J L W R Q W R W K H U H O H Y D Q W D Q F K R U L Q J S R L Q W V
2. / L I W L W D Q G S R V L W L R Q L W L Q W K H Y H K L F O H L Q V L G H W K H H Q J L Q H F R P S D U W P H Q W
3 U R F H H G V O R Z O \ Z K H Q O L I W L Q J W K H H Q J L Q H F K H F N L Q J W K D W W K H H Q J L Q H G R H V Q R W H Q F R X Q W H U R E V W D F O H V Z K L O H
E H L Q J S O D F H G L Q V L G H W K H Y H K L F O H
) L W W K H H Q J L Q H L Q W K H Y H K L F O H Y H U W L F D O O \ P D N L Q J V X U H Q R W W R W L O W L W 3 D \ D W W H Q W L R Q W K D W W K H H Q J L Q H L V
F R U U H F W O \ S R V L W L R Q H G V R W K D W W K H S U R S H O O H U V K D I W D [ O H V K D I W V D Q G K R O H V I R U W K H ¿ [ L Q J V F U H Z V D U H matching.
: + ( 1 3 2 6 , 7 , 2 1 , 1 * 7 + ( ( 1 * , 1 ( ( 1 6 8 5 ( 7 + $ 7 7 + ( 3 , 3 ( 6 6 7 , / / 7 2 % ( & 2 1 1 ( & 7 ( ' $ 5 ( 1 2 7
& 5 8 6 + ( '
3 U R W H F W W K H F D U E R G \ Z L W K U X E E H U J X D U G V V R L W G R H V Q R W E H F R P H G D P D J H G Z K L O H W K H H Q J L Q H L V E H L Q J put in.
Page 234 of 1659
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Fig.23
3
5Q
Q
S
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8
Fig.22
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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
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 $
35 & R Q Q H F W W K H I X V H V R Q W K H U H O D \ V X S S R U W 3 ) L J ).
$ % O D F N $ V H F R Q G D U \ D L U S X P S
% % U R Z Q $ I X H O S X P S V X S S O \
& % O D Q N
' 5 H G $ V H F R Q G D U \ D L U S X P S
36 & R Q Q H F W W K H U H O D \ V R Q W K H V X S S R U W 3 ) L J ).
% O X H P D L Q U H O D \
* U D \ V H F R Q G D U \ D L U S X P S U H O D \
3 X U S O H U H O D \
5 H G U H O D \
2 U D Q J H V H F R Q G D U \ D L U S X P S U H O D \
* U H H Q H Q J L Q H U H O D \
: K L W H ( J H D U S X P S U H O D \ R Q O \ R Q Y H K L F O H V H T X L S S H G Z L W K ( J H D U V \ V W H P
% O D Q N
% O D Q N 37. 7 L J K W H Q W K H V F U H Z V Q-Fig.22 V H F X U L Q J W K H U H O D \ V X S S R U W 3 ) L J ) to the chassis.
) D V W H Q W K H I X V H E O R F N V 5 ) L J ) to the corresponding support.
39. & R Q Q H F W W K H F R Q Q H F W L R Q V R I W K H U H O D \ V S-Fig.23 W R W K H P D L Q H O H F W U L F D O V \ V W H P
40. & R Q Q H F W W K H ( J H D U F R Q W U R O X Q L W F R Q Q H F W R U V T-Fig.23) and tighten the corresponding earth ( 8 ) L J ).Only for
vehicles equipped with an E-gear system.
• Assemble the bench .
• $ V V H P E O H W K H U L J K W V L G H P H P E H U F R Y H U .
• 6 H F X U H W K H U L J K W % S L O O D U F R Y H U .
Page 248 of 1659
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Fig.5
GG
GG
Fig.6
L
H
1
M
1
1
® 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
/ 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
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 $
7.Remove the timing system cover by tightening 4 screws ( G-Fig.5) in the relevant threads so it can be raised.
8. Loosen the 5 screws (
L-Fig.6) securing the shoe and the upper crown gear to remove the oil pump timing chain
( H-Fig.6 ).
9. Loosen the 5 screws ( 1 ) L J ) securing the shoes to remove the main camshaft timing chain ( M-Fig.6).
Page 251 of 1659
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Fig.11
A
® 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
/ 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
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 $
% ' L V D V V H P E O L Q J W K H F U D Q N V K D I W R L O V H D O 3 U H O L P L Q D U \ R S H U D W L R Q V • Disassemble the gearbox (030103).
• ' L V D V V H P E O H W K H F O X W F K D Q G À \ Z K H H O (014103).
' L V D V V H P E O L Q J W K H R L O V H D O1. Remove the oil seal ( A-Fig.11) using the puller.
Page 254 of 1659
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Fig.5
OO
OO
Fig.4
1
M
L
H
L
L
® 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
/ 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
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. Position the main camshaft timing chain ( H-Fig.4) and tighten the 5 screws ( L-Fig.4) securing the shoes.
) D V W H Q L Q J W K H V F U H Z V W L J K W H Q L Q J W R U T X H F
Position the oil pump timing chain ( M-Fig.4) and tighten the 5 screws ( L-Fig.4) securing the shoe and the upper
crown gear.
) D V W H Q L Q J W K H V F U H Z V W L J K W H Q L Q J W R U T X H F
7. Position the timing system cover by tightening the 4 screws ( O-Fig.5) in the relevant threads so it can be
raised.
Page 341 of 1659
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® Automobili Lamborghini S.p.A. / H S U R F H G X U H H O H L Q I R U P D ] L R Q L S X E E O L F D W H G L V H J X L W R V R Q R V W U H W W D P H Q W H F R Q ¿ G H Q ] L D O L H U L Y R O W H H V F O X V L Y D P H Q W H D O O D 5 H W H ' H D O H U H 6 H U Y L F H 3 R L Q W $ X W R U L ] ] D W L / D P E R U J K L Q L 7 X W W L L G L U L W W L G ¶ D X W R U H V R Q R S U R S U L H W j
G L $ X W R P R E L O L / D P E R U J K L Q L 6 S $ L Q E D V H D O O D O H J J H V X L G L U L W W L G ¶ D X W R U H 7 X W W L L F D S L W R O L 3 ' ) G L F X L V L F R P S R Q J R Q R L P D Q X D O L R I ¿ F L Q D : ( % G H V F U L W W L G L V H J X L W R V L E D V D Q R V X O O H L Q I R U P D ] L R Q L G L V S R Q L E L O L D O
P R P H Q W R G H O O D S X E E O L F D ] L R Q H & R Q U L V H U Y D G L D J J L R U Q D P H Q W R H P R G L ¿ F K H 6 R Q R Y L H W D W H O D U L V W D P S D O D U L S U R G X ] L R Q H O ¶ L Q R O W U R D S H U V R Q H Q R Q D X W R U L ] ] D W H H R D W H U ] H S H U V R Q H O D W U D G X ] L R Q H D Q F K H S D U ] L D O H
V H Q ] D O ¶ D X W R U L ] ] D ] L R Q H V F U L W W D G D S D U W H G L $ X W R P R E L O L / D P E R U J K L Q L 6 S $
5 S P O L P L W L Q J G H Y L F H
In normal operating conditions with operative temperatures TH2O 90°C and Toil 90°C, the limiting device is structured
as follows:
in neutral engine limited to 7800 rpm (3500 rpm only for JP and Korea) st
gear U S P
2 nd
gear 8550 rpm
3 rd
gear 8650 rpm
4 th
gear 8500 rpm
5 th
gear 8500 rpm
6 ty
gear U S P
Reverse gear 6000 rpm
The values stated above are indicative and subject to changes introduced in the Factory.
1 R W H It must however be remembered that when the vehicle is hot, idle speed is 680 rpm and it goes up to 820 rpm with the A/C on.
Control and power limitation strategies
The ECU controls rpm limitation using different maps, depending on the environmental conditions at the time: • with engine cold (Water temperature < 60°C) and with low Toil (Oil temperature < 40°C), the rpm are limited
• with engine hot (Water temperature > ƒ & W K H U S P D U H O L P L W H G
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Fig.6
AB
Fig.7
B
B
A
A
® Automobili Lamborghini S.p.A.
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V H Q ] D O ¶ D X W R U L ] ] D ] L R Q H V F U L W W D G D S D U W H G L $ X W R P R E L O L / D P E R U J K L Q L 6 S $
Fuel pump
There is only one electric fuel pump (
A-Fig.6) and it is in the right tank. This pump is controlled by an ECU ( B-Fig.6)
which in turn is controlled by the master control unit.
The pump has an operating pressure ranging between 4 and 6 bar, depending on the various operating conditions
of the vehicle.
The pump sends the fuel to the two high pressure pumps (which are mechanical) that compress the fuel and take the pressure to a value varying from 120 to 140 bar, according to vehicle operation.
Both the high and low pressure pumps are monitored by two sensors installed on the respective lines to prevent overpressure problems. Linear phase transformers
Linear phase transformers allow the engine phase to vary according to the torque required in order to always have optimum phasing.
In this version they are always enabled, and the phasing follows different maps according to the load and the atmospheric conditions. Piloting is performed by a solenoid valve ( A-Fig.7), which makes the oil pass inside the phase-changing gear.
This operation is managed by the injection control units that also receive the position of the camshaft through the
Hall effect sensors ( B-Fig.7) mounted on the camshafts:
• two sensors for the exhaust (one per cylinder bank)
• two sensors for the intake (one per cylinder bank)