engine LAMBORGHINI GALLARDO 2009 Service Manual
Page 224 of 1659
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Fig.9
3
2
3 2
® 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 $
12. Connect the engine – radiator return pipe ( 2 ) L J E \ W L J K W H Q L Q J W K H V F U H Z V V H F X U L Q J W K H À D Q J H
13. 3 R V L W L R Q D Q G F R Q Q H F W W K H R L O W D Q N ± H Q J L Q H S L S H 3 ) L J E \ W L J K W H Q L Q J W K H V F U H Z V V H F X U L Q J W K H À D Q J H
3 R V L W L R Q W K H R L O W D Q N ± H Q J L Q H S L S H 3 ) L J L Q V X F K D Z D \ W K D W L W S D V V H V X Q G H U W K H D [ O H V K D I W W K H R S S R V L W H
H Q G Z L O O E H F R Q Q H F W H G W R W K H R L O W D Q N .
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Fig.17
A
B
C
DD
® 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 $
Laying the engine wiring harness
Keep the battery disconnected while laying the engine wiring harness.
23. & R Q Q H F W W K H ( 1 & 6 Y D O Y H F R Q Q H F W R U A-Fig.17 L Q W K H U H D U S D U W R I W K H Y H K L F O H
24. Connect the pump connector ( B-Fig.17 V H F X U H W K H F D Q L V W H U ¿ O W H U C-Fig.17 E \ ¿ [ L Q J W K H W K U H H V X S S R U W V D-
Fig.17 ).
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) L J
(
*
*
F
® 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 $
25. Connect the earth cable on the right side of the engine compartment ( ( ) L J ).
26. & R Q Q H F W W K H W Z R F O D P S V ) ) L J V H F X U L Q J W K H H Q J L Q H Z L U L Q J K D U Q H V V W R W K H U L J K W V H F R Q G D U \ D L U S L S H
27. & R Q Q H F W W K H U L J K W V H F R Q G D U \ D L U S X P S F R Q Q H F W R U * ) L J ).
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Fig.24
B
C
Fig.25
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 $
Assembling the engine cross member • $ V V H P E O H W K H H Q J L Q H R L O W D Q N (011505).
41. Position the engine cross member ( A-Fig. 24).
42. Position the spacers ( B-Fig.24 L Q W K H H Q J L Q H F U R V V P H P E H U V X S S R U W S R L Q W V R Q W K H F K D V V L V
8 V H W K H V D P H V S D F H U V U H P R Y H G G X U L Q J W K H G L V D V V H P E O \ V W D J H D Q G U H S R V L W L R Q W K H P L Q W K H V D P H S R V L W L R Q .
43. ) D V W H Q W K H F U R V V P H P E H U E \ W L J K W H Q L Q J W K H O D W H U D O V F U H Z V S H U V L G H (C-Fig.25 ).
Page 236 of 1659
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Fig.26
D
® 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 $
44. & R Q Q H F W W K H Z L U L Q J K D U Q H V V D-Fig.26) to the cross member using its mounting clamps.
2 Q F H W K H H Q J L Q H F U R V V P H P E H U L V V H F X U H G L W L V S R V V L E O H W R L Q V W D O O :
• S R Z H U V W H H U L Q J R L O W D Q N D Q G L W V V X S S R U W E U D F N H W (042305).
• Y D F X X P W D Q N D Q G L W V V X S S R U W E U D F N H W (061105).
• Assemble the rear torsion bar (051005).
• Assemble the exhaust silencer (025105).
• $ V V H P E O H W K H D L U ¿ O W H U D V V H P E O \ (013305).
• $ V V H P E O H W K H F R R O D Q W W D Q N Q R X U L F H (012105).
• ) L O O W K H F R R O D Q W W D Q N .
• ) L O O W K H D L U F R Q G L W L R Q L Q J V \ V W H P W D Q N .
• ) L O O W K H H Q J L Q H R L O W D Q N .
• ) L O O W K H S R Z H U V W H H U L Q J R L O W D Q N .
• Assemble the upper panel .
• $ V V H P E O H W K H U H D U Z K H H O D U F K .
• Assemble the internal panels of the engine compartment .
• Assemble the engine hood .
• Assemble the rear bumper .
• Assemble the rear combination lights (094505).
• $ V V H P E O H W K H U H D U Z K H H O V (060105).
• $ V V H P E O H W K H F D U À R R U V .
• & R Q Q H F W W K H E D W W H U \ (091503).
7 K H / D 5 D $ 6 (109000) E D V L F V H W W L Q J S U R F H G X U H K D V W R E H V W D U W H G H Y H U \ W L P H D Q H Q J L Q H R U R Q H R U E R W K
L Q M H F W L R Q F R Q W U R O X Q L W V D U H U H S O D F H G 1. E D V L F V H W W L Q J R Q W K H P D V W H U D Q G V O D Y H F R Q W U R O X Q L W D G D S W V W K H W K U R W W O H V
2. E D V L F V H W W L Q J D G D S W V W K H W X P E O H Y D O Y H V
3. E D V L F V H W W L Q J D Q G D G D S W W K H L Q W D N H D Q G H [ K D X V W F D P V K D I W V R O H Q R L G Y D O Y H V
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C3C9C15C10C4
C1C7C13C12C6
C2
C8C14C16C11C5
B
Fig.1
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 K H D G V 3 U H O L P L Q D U \ R S H U D W L R Q V • Disassemble the engine (010003)
• Disassemble the Exhaust manifold (013103)
• Disassemble the coils (090503)
• Disassemble the variable valve timing mechanisms (011603)
Adopt the safety procedure to reduce the fuel pressure in the supply circuit (012803).
' L V D V V H P E O L Q J W K H U L J K W D Q G O H I W K H D G F R Y H U V 1. Disconnect the supply circuit pipe ( A-Fig.1) from the high pressure pump.
2. Free the 2 head covers ( B-Fig.1) from the 2 heads (one cover per head) by removing all 32 screws (16 screws
per cover).
5 H P R Y H W K H V F U H Z V R I H D F K K H D G I R O O R Z L Q J W K H D V F H Q G L Q J R U G H U I U R P & W R & V K R Z Q L Q ) L J
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Fig.1
A
Fig.2
C3C1C7C9C5C11
C12C6C4C2C8C10
B
® 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 $
Assembling the heads $ V V H P E O L Q J W K H K H D G J D V N H W 1. Position the gaskets ( A-Fig.1) on the 2 cylinder banks (1 gasket per cylinder bank), positioning them correctly
using the centering dowels.
Assembling the heads2. Position the 2 heads ( B-Fig.2) on the respective cylinder banks.
3. Secure the heads to the crankcase by means of the 12 screws, following the ascending order from C1toC12
shown in Fig.2.
Use engine oil in advance to lubricate the thread of the screws.
7 L J K W H Q L Q J W R U T X H R I V F U H Z V W L J K W H Q L Q J W R U T X H F .
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Fig.7
M13M7M2M8M14
M11M5M4M10M16
M12
M6M1M3M9M15
L 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 $
$ V V H P E O L Q J W K H U L J K W D Q G O H I W K H D G F R Y H U V 1. Assemble the 2 head covers ( L-Fig.7) on the 2 heads (one cover per head).
2. Tighten the 2 covers using the 32 screws (16 screws per cover).
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
7 L J K W H Q W K H V F U H Z V R I H D F K K H D G I R O O R Z L Q J W K H D V F H Q G L Q J R U G H U I U R P 0 W R 0 V K R Z Q L Q ) L J
3 O D F H W K H E X V K L Q J V D Q G V S H F L D O J D V N H W V E H W Z H H Q W K H V F U H Z V Z K H Q W L J K W H Q L Q J
3. Connect the supply circuit pipe to the high pressure pump ( 1 ) L J ).
) D V W H Q L Q J W K H X Q L R Q W L J K W H Q L Q J W R U T X H G .
• Assemble the variable valve timing mechanisms
• Assemble the coils
• Assemble the exhaust manifolds
• Assemble the engine
Page 245 of 1659
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Fig.1
BAC
C
C
C
® 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 D Q G E H D U L Q J V 3 U H O L P L Q D U \ R S H U D W L R Q V • Disassemble the engine (010003).
• Disassemble the exhaust manifold (013103).
• Disassemble the coils (090503)
• Disassemble the variable valve timing mechanisms (011603).
• Disassemble the heads (010303).
• Disassemble the oil pump (011503).
' 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 D Q G E H D U L Q J V1. Loosen the 20 screws ( A-Fig.1) securing the timing system cover.
2. Loosen the 6 crosshead screws ( B-Fig.1) securing the timing system cover.
3. Tighten the 4 screws in the relevant threads ( C-Fig.1) so the timing system cover can be raised .
4. Remove the chains that transmit motion to the camshafts.
The chain transmitting motion to the right camshafts is shorter than the left chain.
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Page 246 of 1659
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Completely upturn the engine.
4. / R R V H Q W K H ¿ [ L Q J V F U H Z V ' ) L J ) and remove the alternator support.
5. Loosen the 20 crosshead screws ( ( ) L J ) securing the oil pan to the crankcase.