gearbox LAMBORGHINI GALLARDO 2009 Repair Manual
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® Automobili Lamborghini S.p.A.
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B) Disassembling the accelerator pedal cluster
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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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B) Assembling the accelerator pedal cluster
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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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% $ 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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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 )
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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).
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3 R V Value Function 3 R Z H U
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
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The “Basic setting” function allows you to make the initial settings on the selected control unit (E-GEAR).
The settings are divided into 7 different block numbers (Routines). Clutch Kiss Point Self tuning (Routine 1)
1 R W H
Routine 1 is performed when: • the clutch is replaced
• the E-gear control unit is replaced
• the gearbox is removed and reassembled
• Turn the ignition key to ON.
• Connect the computer to the diagnosis outlet OBDII
• Select routine 1 inside the block number ( A-Fig.9).
• Start the engine and bring water temperature to > 60°C.
• Start the connection (
) and press the start push-button ( B-Fig.9).
Routine 1 readapts the position of the clutch and calculates the correct Kiss Point value.
line 1 displays the operation result:
0 = positive result (Kiss Point successfully calculated)
255 = non-compliant result
line 2 displays the Kiss Point value at the end of the procedure
line 3 displays the engine speed, expressed in rpm
line 4 displays the clutch speed, expressed in rpm (the value ranges between 0 and 130); the speed at the time
when the clutch starts to transmit the engine’s motion.
The system performs the approach operation 10 times in order to properly calibrate the Kiss Point
value.
In order to store the Kiss Point value that has just been calculated in the system, turn the ignition key to OFF and
wait about one minute to allow the control unit to turn itself off (check this value in MWB 10).
: K H Q W K H S U R F H G X U H L V ¿ Q L V K H G W K H V \ V W H P D O Z D \ V D X W R P D W L F D O O \ U H V W R U H V W K H . L V V 3 R L Q W Y D O X H H Y H U \ W L P H W K H Y H K L F O H is started (when certain temperature and operating conditions are reached) to keep the pickup of the vehicle in
optimum condition according to clutch wear.
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Fig.10
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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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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 $
Grid Self tuning (Routine 2)
1 R W H
Routine 2 is performed when: • the clutch is replaced
• the E-gear control unit is replaced
• the gearbox is removed and reassembled
• Turn the ignition key to ON.
• Connect the computer to the diagnosis outlet OBDII
• Select routine 2 inside the block number ( A-Fig.10).
• Start the connection (
) and press the start push-button ( B-Fig.10).
Routine 2 lets you set the engagement /selection grid regarding the gears.
line 1 the values “1” and “2” indicating the odd and even gears, respectively, that are engaged are displayed
intermittently during operation.
it displays the following values at the end of the operation:
14 = positive result (engagement /selection grid performed)
8 = non-compliant result (grid not performed due to electrical problems)
9 = non-compliant result (grid not performed because idle gears are not found)
line 2 displays the operation result:
0 = unacceptable grid
1 = acceptable grid
In order to store the grid value, turn the ignition key to OFF and wait for approx. 1 minute to allow the control unit to
turn off (check this value in MWB 64).
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Abb.12
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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 $
Neutral Engagement (Routine 4)
1 R W H
Routine 4 is performed when: • the clutch is replaced
• the gearbox is removed and reassembled
• Turn the ignition key to OFF and wait about one minute to allow the control unit to turn itself off, then turn the
key back to ON.
• Connect the computer to the diagnosis outlet OBDII
• Select routine 4 inside the block number ( A-Fig.12).
• Start the connection (
) and press the start push-button ( B-Fig.12).
Routine 4 checks if the position of the idle gear is correct (the condition is checked only if a correct gear engagement
grid has been created – Routine 2 -).
riga 1 displays the operation result:
3 / 14 = gear in neutral
9 = idle gear not found
Page 1448 of 1659
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Fig.13
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Hydraulic circuit discharge (Routine 5)
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Routine 5 is performed when:
• the E-gear oil level is checked
• gearbox is replaced
• the E-gear kit is replaced
• Turn the ignition key to OFF and wait about one minute to allow the control unit to turn itself off, then turn the
key back to ON.
• Connect the computer to the diagnosis outlet OBDII
• Select routine 5 inside the block number ( A-Fig.13).
• Start the connection (
) and press the start push-button ( B-Fig.13).
Routine 5 empties the pressure inside the E-gear circuit.
line 1 displays activation of the solenoid valve:
0 = not activated
1 = activated
line 2 displays the pressure value (during the pressure release phase, it continuously drops until it reaches
value 0)
line 3 displays the clutch status:
1 = activated
0 = not activated
line 4 displays the status of the hydraulic circuit:
1 = activated
0 = not activated
When the pressure reaches 0 bar, you can work on the circuit without risking pressure leaks.
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Work on the circuit with the key OFF. If you turn the ignition key to ON, the system automatically brings pressure back inside the circuit.