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Lamborghini Gallardo 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Lamborghini Model: Gallardo Year: 2004 Codes Vin Prefix: ZHW 👋 Introduction Market Position Target Audience: Owner with basic mechanical skills and independent auto service professionals, as well as informed owners. Competitive Analysis Uniqueness: Vehicle-specific, not generic; contains the exact same information used by authorized dealer service departments. Key Features Content Type: Step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications. Value Proposition Cost Savings: Enables DIY repairs to save significant money on maintenance and repair bills. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Page Count Estimated Page Count: Varies by specific edition, but comprehensive workshop manuals for exotics typically range from 1500-3000+ pages. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete service and repair for engine systems, including disassembly, inspection, and reassembly of all major components. Engine Electrical: Detailed wiring schematics, diagnostic procedures, and repair instructions for all engine-related electrical systems and components. Emission Control: Information on emission control systems, catalytic converters, oxygen sensors, and associated diagnostic troubleshooting. Fuel System: Service procedures for fuel injection, fuel pumps, fuel filters, and fuel pressure diagnostics. Clutch System: Repair and adjustment procedures for the clutch assembly, including hydraulics and mechanical components. Manual Transaxle: Step-by-step instructions for servicing, diagnosing, and repairing the manual transaxle. Automatic Transaxle: Comprehensive repair and diagnostic information for the automatic transaxle, including torque converter and valve body. Driveshaft Axle: Service and repair of driveshafts, CV joints, and axles. Suspension System: Detailed information on suspension components, alignment procedures, and repair of shock absorbers, springs, and control arms. Steering System: Repair and adjustment procedures for the power steering system, steering rack, and tie rods. Restraint System: Information on airbags, seatbelts, and associated electronic control units. Brake System: Comprehensive service and repair for the braking system, including ABS, EBD, and parking brake. Body Interior Exterior: Repair procedures for body panels, doors, windows, seats, and interior trim. Body Electrical: Wiring diagrams and troubleshooting for lighting, power accessories, and body control modules. HVAC System: Service and repair for the heating, ventilation, and air conditioning systems. Procedures Included Maintenance: Step-by-step instructions for routine maintenance tasks such as oil changes, filter replacements, and fluid checks. Troubleshooting: Diagnostic procedures and symptom-based troubleshooting guides for common and uncommon issues. Repair: Detailed, step-by-step repair instructions for all major vehicle systems, suitable for both internal and external mechanics. Technical Depth Diagnostic Capabilities: Covers advanced diagnostics, component testing, and electrical system troubleshooting. Rebuild Procedures: Includes detailed procedures for engine and transmission rebuilds. 📊 Manual Specifications File Format Compatibility: All Versions of Windows and Mac Requirements: Adobe PDF Reader Print Quality Printability: Yes, all pages are printable. Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 5.0L V10 Naturally Aspirated Engine Code: L539 (for early models) Performance Horsepower: Approximately 500 PS (493 hp; 368 kW) at 7,500 rpm Torque: Approximately 510 Nm (376 lb-ft) at 5,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Engine Features Valvetrain: DOHC, 4 valves per cylinder with variable valve timing 🔧 Transmission Standard Transmission Type: 6-Speed Manual Transaxle Optional Transmission Type Optional: 6-Speed 'E-Gear' Automated Manual Transmission (with paddle shifters) Features Drive System: All-Wheel Drive (AWD) with viscous coupling center differential and limited-slip rear differential Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL rating and viscosity (e.g., SAE 75W-90 GL-5 is common for performance transmissions). E Gear Transmission Fluid: Specific hydraulic fluid for E-Gear system, consult manual for part number and type. 📐 Dimensions Exterior Length: Approximately 4,300 mm (169.3 in) Width: Approximately 1,900 mm (74.8 in) Height: Approximately 1,180 mm (46.5 in) Weights Curb Weight: Approximately 1,560 kg (3,439 lb) for manual transmission Wheels Tires Wheelbase: Approximately 2,560 mm (100.8 in) Front Tire Size: 225/40 ZR18 Rear Tire Size: 285/30 ZR18 Wheel Bolt Pattern: 5x112 🛡️ Safety Features Ratings Crash Test Results: Specific official crash test ratings may not be as readily available as for mass-market vehicles; focus on built-in safety features. Active Features ABS: Yes, Anti-lock Braking System Ebd: Yes, Electronic Brakeforce Distribution Traction Control: Yes, Traction Control System (TCS) Passive Features Airbags: Driver and passenger airbags, potentially side airbags. Seatbelts: Three-point seatbelts with pre-tensioners. 💡 Technology Features Infotainment Audio System: Premium audio system (e.g., Pioneer or Alpine depending on options), often with CD player. Navigation: Optional navigation system available. Driver Assistance Parking Sensors: Optional parking sensors for front and rear. Connectivity Bluetooth: Optional Bluetooth connectivity for hands-free calling. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 km (6,000-9,000 miles) or annually, whichever comes first, but consult manual for specifics. Major Service Interval: Major services involving spark plugs, belts, and fluid flushes typically occur at 30,000-60,000 km (20,000-40,000 miles) intervals. Fluid Specifications Engine Oil Specification: Refer to manual for specific viscosity and API/ACEA specifications...
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Lamborghini Gallardo 2004 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Lamborghini
Model:
Gallardo
Year:
2004
Codes
Vin Prefix:
ZHW
👋 Introduction
Market Position
Target Audience:
Owner with basic mechanical skills and independent auto service professionals, as well as informed owners.
Competitive Analysis
Uniqueness:
Vehicle-specific, not generic; contains the exact same information used by authorized dealer service departments.
Key Features
Content Type:
Step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications.
Value Proposition
Cost Savings:
Enables DIY repairs to save significant money on maintenance and repair bills.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
Varies by specific edition, but comprehensive workshop manuals for exotics typically range from 1500-3000+ pages.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete service and repair for engine systems, including disassembly, inspection, and reassembly of all major components.
Engine Electrical:
Detailed wiring schematics, diagnostic procedures, and repair instructions for all engine-related electrical systems and components.
Emission Control:
Information on emission control systems, catalytic converters, oxygen sensors, and associated diagnostic troubleshooting.
Fuel System:
Service procedures for fuel injection, fuel pumps, fuel filters, and fuel pressure diagnostics.
Clutch System:
Repair and adjustment procedures for the clutch assembly, including hydraulics and mechanical components.
Manual Transaxle:
Step-by-step instructions for servicing, diagnosing, and repairing the manual transaxle.
Automatic Transaxle:
Comprehensive repair and diagnostic information for the automatic transaxle, including torque converter and valve body.
Driveshaft Axle:
Service and repair of driveshafts, CV joints, and axles.
Suspension System:
Detailed information on suspension components, alignment procedures, and repair of shock absorbers, springs, and control arms.
Steering System:
Repair and adjustment procedures for the power steering system, steering rack, and tie rods.
Restraint System:
Information on airbags, seatbelts, and associated electronic control units.
Brake System:
Comprehensive service and repair for the braking system, including ABS, EBD, and parking brake.
Body Interior Exterior:
Repair procedures for body panels, doors, windows, seats, and interior trim.
Body Electrical:
Wiring diagrams and troubleshooting for lighting, power accessories, and body control modules.
HVAC System:
Service and repair for the heating, ventilation, and air conditioning systems.
Procedures Included
Maintenance:
Step-by-step instructions for routine maintenance tasks such as oil changes, filter replacements, and fluid checks.
Troubleshooting:
Diagnostic procedures and symptom-based troubleshooting guides for common and uncommon issues.
Repair:
Detailed, step-by-step repair instructions for all major vehicle systems, suitable for both internal and external mechanics.
Technical Depth
Diagnostic Capabilities:
Covers advanced diagnostics, component testing, and electrical system troubleshooting.
Rebuild Procedures:
Includes detailed procedures for engine and transmission rebuilds.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows and Mac
Requirements:
Adobe PDF Reader
Print Quality
Printability:
Yes, all pages are printable.
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
5.0L V10 Naturally Aspirated
Engine Code:
L539 (for early models)
Performance
Horsepower:
Approximately 500 PS (493 hp; 368 kW) at 7,500 rpm
Torque:
Approximately 510 Nm (376 lb-ft) at 5,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Features
Valvetrain:
DOHC, 4 valves per cylinder with variable valve timing
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transaxle
Optional
Transmission Type Optional:
6-Speed 'E-Gear' Automated Manual Transmission (with paddle shifters)
Features
Drive System:
All-Wheel Drive (AWD) with viscous coupling center differential and limited-slip rear differential
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL rating and viscosity (e.g., SAE 75W-90 GL-5 is common for performance transmissions).
E Gear Transmission Fluid:
Specific hydraulic fluid for E-Gear system, consult manual for part number and type.
📐 Dimensions
Exterior
Length:
Approximately 4,300 mm (169.3 in)
Width:
Approximately 1,900 mm (74.8 in)
Height:
Approximately 1,180 mm (46.5 in)
Weights
Curb Weight:
Approximately 1,560 kg (3,439 lb) for manual transmission
Wheels Tires
Wheelbase:
Approximately 2,560 mm (100.8 in)
Front Tire Size:
225/40 ZR18
Rear Tire Size:
285/30 ZR18
Wheel Bolt Pattern:
5x112
🛡️ Safety Features
Ratings
Crash Test Results:
Specific official crash test ratings may not be as readily available as for mass-market vehicles; focus on built-in safety features.
Active Features
ABS:
Yes, Anti-lock Braking System
Ebd:
Yes, Electronic Brakeforce Distribution
Traction Control:
Yes, Traction Control System (TCS)
Passive Features
Airbags:
Driver and passenger airbags, potentially side airbags.
Seatbelts:
Three-point seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Premium audio system (e.g., Pioneer or Alpine depending on options), often with CD player.
Navigation:
Optional navigation system available.
Driver Assistance
Parking Sensors:
Optional parking sensors for front and rear.
Connectivity
Bluetooth:
Optional Bluetooth connectivity for hands-free calling.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or annually, whichever comes first, but consult manual for specifics.
Major Service Interval:
Major services involving spark plugs, belts, and fluid flushes typically occur at 30,000-60,000 km (20,000-40,000 miles) intervals.
Fluid Specifications
Engine Oil Specification:
Refer to manual for specific viscosity and API/ACEA specifications (likely a high-performance synthetic, e.g., 5W-40 or 10W-40).
Coolant Specification:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Consult manual for specific Lamborghini-approved coolant.
Brake Fluid Specification:
DOT 4 or DOT 5.1 high-performance brake fluid.
Known Issues
Clutch Wear:
Clutch wear can be significant depending on driving style, especially with E-Gear models.
E Gear Actuator:
Potential issues with the E-Gear hydraulic actuator and pump system.
Suspension Components:
Wear on certain suspension bushings and ball joints due to high performance and weight.
📚 Vehicle History
Brand Heritage
Brand Origin:
Lamborghini is an Italian manufacturer of luxury sports cars and SUVs, founded by Ferruccio Lamborghini in 1963.
Model Evolution
Gallardo Introduction:
The Gallardo was first introduced in 2003 as a more accessible V10-powered model than the V12-powered Murciélago, targeting a broader segment of the supercar market.
2004 Model Year Significance:
The 2004 model year represents the early production phase of the Gallardo, establishing its platform and core mechanicals.
Production
Manufacturing Location:
Sant'Agata Bolognese, Italy
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
While specific awards for the 2004 model are less documented than later iterations, the Gallardo itself was widely praised for its performance and styling, establishing Lamborghini's presence in the entry-level supercar market.
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