clutch LAMBORGHINI GALLARDO 2009 Workshop Manual
Page 3 of 1659
3
L714 00 00 00
® 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 $
0 D L Q J U R X S 6 X E J U R X S 7 L W O H L G H Q W L ¿ F D W L R Q
01Engine 00 $ V V H P E O L H V 00Description
01 $ X [ L O L D U \ E H O W 01Check (control)
03Crankcase, cylinder, cylinder head 02Adjustment
05Crankshaft, connecting rods 03 ' L V D V V H P E O H
07Pistons, rings, pins, liners 04Cleaning
09Camshaft, valves 05 $ V V H P E O H
15Oil pump 06Bleeding
16 9 D U L D E O H Y D O Y H W L P L Q J P H F K D Q L V P
07 ) O X L G V V X E V W L W X W L R Q
17Oil cooler 08Filling and topping up
19Air intercooler 09Overhaul
21Water cooling 10Error code
22Water pump 11
0 H D V X U H P H Q W E O R F N U H D G L Q J R U S D U D P H W H U V
27Fuel pump & lines 12Running-in
28Injection system 13Adjustment coding
29Air intake manifold 14
' L D J Q R V L V V R I W Z D U H
30 2 L O ¿ O W H U
31Catalyst
33 , Q W D N H D L U ¿ O W H U
41 & O X W F K ) O \ Z K H H O
42Automatic clutch (E-gear)
45 7 X U E R F K D U J H U
90Timing system
98Repair kit
99 ) L [ L Q J D Q G V X V S H Q V L R Q
Page 14 of 1659
14
L714 00 00 00
® 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 $
0 D L Q J U R X S 6 X E J U R X S 7 L W O H L G H Q W L ¿ F D W L R Q
71 5 H W U R ¿ W 2 S W L R Q D O 00 $ V V H P E O L H V 00Description
Engine 01 $ X [ L O L D U \ E H O W 01Check (control)
03Crankcase, cylinder, cylinder head 02Adjustment
05Crankshaft, connecting rods 03 ' L V D V V H P E O H
07Pistons, rings, pins, liners 04Cleaning
09Camshaft, valves 05 $ V V H P E O H
15Oil pump 06Bleeding
16 9 D U L D E O H Y D O Y H W L P L Q J P H F K D Q L V P
07 ) O X L G V V X E V W L W X W L R Q
17Oil cooler 08Filling and topping up
19Air intercooler 09Overhaul
21Water cooling 10Error code
22Water pump 11
0 H D V X U H P H Q W E O R F N U H D G L Q J R U S D U D P H W H U V
27Fuel pump & lines 12Running-in
28Injection system 13Adjustment coding
29Air intake manifold 14
' L D J Q R V L V V R I W Z D U H
30 2 L O ¿ O W H U
31Catalyst
33 , Q W D N H D L U ¿ O W H U
41 & O X W F K ) O \ Z K H H O
42Automatic clutch (E-gear)
45 7 X U E R F K D U J H U
90Timing system
98Repair kit
99 ) L [ L Q J D Q G V X V S H Q V L R Q
Page 57 of 1659
15
' ' L D E O R 0 0 X U F L H O D J R * * D O O D U G R
00 02 00
13a
13b
13c
& R G H ' H V F U L S W L R Q ' 0 * 3 K R W R
® 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 $
Transmission
962195007 Clutch centring tool
& O R V H W
' U D Z H U 3 R V L W L R Q D
962495019 Gearbox cover mock-up block
& O R V H W
' U D Z H U 3 R V L W L R Q E
962495032 Gearbox ratchet adjustment gauge
& O R V H W
' U D Z H U 3 R V L W L R Q F
Page 63 of 1659
21
00 02 00
19a
19b
19c
& R G H ' H V F U L S W L R Q ' 0 * 3 K R W R
® 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 $
62451005 Gasket punch
& O R V H W
' U D Z H U 3 R V L W L R Q D
62451006 Clearance gauge
& O R V H W
' U D Z H U 3 R V L W L R Q E
62195015 Clutch aligning tool & O R V H W
' U D Z H U 3 R V L W L R Q F
Page 100 of 1659
1
L714 00 05 00
® 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 $
* H D U E R [ For vehicles equipped with manual gearbox:•6 quick clutch ratios with cable control.
Gear ratios
1st gear 1 : 3,313
2nd gear 1 : 2,053
3rd gear 1 : 1,458
4th gear 1 : 1,138
5th gear 1 : 0,939
6th gear 1 : 0,784
Reverse 1 : 2,813
Page 111 of 1659
9a
9b
9c
9d
L714 00 08 00
9
A
A
B
A
C
A
B
DESCRIPTION TIGHTENING TORQUE (Nm) PICTURE
® 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 $
Tightening the connecting rod cap – connecting rod beam
A. Tightening torque 40 ± 3
+
120° ± 10°
EXCEL 079100991D
Tightening the power steering pump support A. Tightening torque 8
PDM 400422-038
Tightening the clutch actuator support and sensor
A. Tightening torque 6 ± 3%
B. Tightening torque 6 ± 3%
EXCEL 079100991D
7 L J K W H Q L Q J W K H W L P L Q J V \ V W H P S D U W V R Q W R W K H F U D Q N F D V H A. Tightening torque 42 ± 5%
B. Tightening torque 10 ± 5%
C. Tightening torque 10 ± 5%
EXCEL 079100991D
Page 114 of 1659
12a
12b
12c
12d
L714 00 08 00
12
A
AA
A
A
DESCRIPTION TIGHTENING TORQUE (Nm) PICTURE
® 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 $
) D V W H Q L Q J W K H S D U N L Q J E U D N H
A. Tightening torque of screw 15
PDM 400609-072
Tightening the clutch hose hollow screw A. Tightening torque 35 ± 5%
PDM 086300-018
7 L J K W H Q L Q J W K H Y D U L D E O H Y D O Y H W L P L Q J F R Y H U V F U H Z V
A. Tightening torque 10 ± 5%
EXCEL 079100991D
7 L J K W H Q L Q J W K H K H D G V F U H Z V R Q W R W K H F U D Q N F D V H A. Tightening torque 10 ± 5%
EXCEL 079100991D
Page 344 of 1659
7
L714 01 28 00
Fig.7
A
B
C
C
5
F
'
GH
GH
QL
1
M
O 3
3
,
(
® 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 $
Sensor
A
Speed sensor
B * H D U V S R V L W L R Q V H Q V R U V
C Secondary air pressure sensors
' Low fuel pressure sensor output
( Wiv pressure sensor output
F Oil pressure sensor output
G CAM sensors output
H Exhaust phase sensors output
, Intake phase sensors output
L Coolant temperature sensor output
M Air temperature sensor
1 A/C sensor
O Clutch pump sensor
3 $ , 5 % $ * V H Q V R U V
Q Coolant level sensor
5 Oil level and temperature sensor
Page 392 of 1659
1
L714 01 41 00
Fig.1
D
E
F
CBA
® 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 $
Clutch technical data •
7 Z R S O D W H G U \ F O X W F K Z L W K À H [ L E O H F R X S O L Q J D Q G G L D S K U D J P V S U L Q J
• 7 K U X V W L Q J P H F K D Q L V P
• 6 H O I D G M X V W L Q J K \ G U D X O L F G L V H Q J D J H P H Q W G L V H Q J D J H P H Q W W D N H V S O D F H E \ D W K U X V W E H D U L Q J K \ G U D X O L F D O O \ F R Q W U R O O H G
E \ D G H Y L F H L Q V L G H W K H F O X W F K E H O O
Clutch technical data
* D V N H W R X W H U G L D P H W H U
* D V N H W L Q Q H U G L D P H W H U P P
& O X W F K G L V N W K L F N Q H V V Z L W K 1 O R D G ·
0 D [ G L V N Z H D U
7 K U X V W E H D U L Q J P D [ V W U R N H “
Clutch pump technical data
3 L V W R Q E R U H
7 R W D O V W U R N H
Clutch (Fig.1)
A. Flywheel
B. & O X W F K G L V N D Q G S U H V V X U H S O D W H D V V H P E O \
C. & O X W F K V O H H Y H D Q G W K U X V W E H D U L Q J D V V H P E O \
D. & O X W F K S X P S
E. & O X W F K E O H H G H U
F. & O X W F K F R Q W U R O S L S H V
Page 393 of 1659
1
L714 01 41 02
Fig.1 Fig.2
B
A
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 $
Adjusting the clutch pedal 3 U H O L P L Q D U \ R S H U D W L R Q V •
Adjust the brake pedal (092702).
Adjusting the pedal
1. Place the clutch pedal ( A-Fig.1) at the same height as the brake pedal ( B-Fig.1).
2. Using the adjustment screw ( C-Fig.2), raise the clutch pedal approximately 2-3 mm higher than the brake
pedal.