2009 LAMBORGHINI MURCIÉLAGO ESP
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® 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 $
8 ' L V D V V H P E O L Q J S L O O D U $ 3 U H O L P L Q D U \ R S H U D W L R Q V •
Disassemble pillar C 3 R L Q W 7 .
' L V D V V H P E O L Q J S L O O D U $
1. 3 U L ] H X S W K H H G J H R I W K H S L O O D U $ W R U H O H D V H W K H ¿ Q Q H G D Q F K R U V $ ) L J ) securing it from their housings and
to release the slot ( % ) L J ) from its corresponding coupling.
2. Remove pillar A ( & ) L J ).
$ O Z D \ V W D N H W K H X W P R V W F D U H Q R W W R G D P D J H W K H O H D W K H U X S K R O V W H U \ G X U L Q J G L V D V V H P E O \ S U R F H G X U H V
Page 912 of 1173
Automobili Lamborghini
DEUTSCHActionplan paint shop: alle Lackierer
Subjekt: Quality, Paintig, FinishStand: 24.08.05
ResponsibleSubjektPossible mistakesMeasure to preventArea
DeliveryVerschmutzte KarossenBei Lieferung die Karossen auf Schäden überprüfen, Karosse AbdeckenCompleted Body KTL rauh, verschmutzt, Schleifriefen, Überbeschichtet KTL auf Schleifriefen, verschmutzung, einschlüsse, Läufer, Rost, Schichtdicke Prüfen
KTL-läufer und verkrustungen am Rahmen, Korrosion Carbonteile auf freigelegte Stellen, Kratzer, Poren, Dellen, Löcher, nachgebesserte
Porosität auf Carbonteilen stellen, Spachtelstellen überprüfen
freigelegtes Carbon (nacharbeit an ecken zb.) Stahlteile auf Schäden, Dellen, Kratzer, Schleifriefen, Kanten Prüfen
EP-primer rauh, ausgebessert, mit fehlstellen EP-primer auf gute Oberflähe und Fehlstellen Prüfen
Fehlstellen aus dem Untergrund, löcher, dellen Entscheiden, welche Fehlstellen ohne übermäßigen Aufwand Abgearbeitet werden
Stahlteile mit Beulen, Dellen, Kratzern, Schleifriefen können, Aufzeichnung der Fehlstellen auf einem "Karossenblatt"Kratzer auf den Teilen Lieferanten und Lamborghini über Fehler informieren.
Abdichtung der Karosse Korrekt Bei groben Fehlern mit Lamborghini entscheiden, wie Fehler beseitigt werden soll.
PreparationFehlstellen im und unter KTL nicht beseitigtVor Arbeitsbeginn Karosse gründlich Reinigen.Steelparts Porosität an Spachtelstellen Fehler im und auf dem KTL und Fehler im Blech erkennen und komplett beseitigen, sichtbare Schleifriefen auf der Oberfläche wenn Fehler zu groß ist, Lamborghini und Lieferanten Informieren.
Schlechte Lackhaftung an ecken und kanten Fehler in und auf den Carbonteilen erkennen und komplett beseitigen, wenn Fehler zu groß ist, Lamborghini und Lieferanten Informieren.
Carbonparts
Porosität aus dem Carbon, Spachtelstellen so klein wie mögich halten, geringe Spachtel Schichtdicke einhalten
mangelnder kontakt zwischen EP-primer und Carbon Spachtelporen vermeiden, Grobe Schleifspuren gering halten und fein Ausschleifen
Kratzer, Lunken, Löcher, Offenes Carbon,(zb: P80, P120, P180, P240) Kontrollpulver benutzen (3M).
Spachtel unter EP-primer, EP-primer rauh mit Alle Flächen, ecken und Kanten fein nachschleifen (P240)
nachgebeserten stellen, Freigelegte Carbonfasern Alle ecken und Kanten gründlich Anschleifen (3M Schleifpad) Blankes Metall nicht mit den Händen berühren, Metall mit Washprimer grundieren
Durchschliffstellen auf Carbon vor PU-primer auftrag mit EP-primer Grundieren
Danach nicht mehr auf das Carbon durchschleifen.
vor PU-primer / Wash-primer Applikation die Oberfläche sehr gut reinigen, Entfettenund Abtrocknen lassen.Abschließend genau auf Fehler kontrollieren und Fehler beseitigen.
Alle Arbeitsschritte Dokumentieren.
PreparationFalscher Primer auf falschem MaterialPrimermaterial nach dem Untergrund auswählen (Metall / Carbon)Primer Applikation Vertauschen von einzel Komponenten der Primer zubereitung des Primer-material nach Technischen Merkblätternnicht korreckte Anmischung des MaterialsTopfzeiten und Lagerzeiten nicht überschreiten
Anwendungszeitraum überschritten Schichtdicken beachten, nicht überbeschichten.
Oberfläche schlecht gereinigt / Staubig Ablüftzeiten zwischen den Lackiergängen nicht überschreiten / unterschreiten
Trockentemperatur zu gering / zu hoch Trockenzeiten und Trockentemperaturen einhalten
Trockenzeit zu kurz / zu lang Vor Primerauftrag prüfen ob die Oberfläche gereinigt ist
Schichtdicke zu hoch / zu gering Abschließend genau auf Fehler kontrollieren und Fehler beseitigen.
Ablüftzeiten nicht eingehalten Alle Arbeitsschritte Dokumentieren.
PreparationPoren aus dem UntergrundAlle Poren finden und vor dem Schleifen füllen.Primer sanding / grinding noch sichtbare Schleifriefen vom Untergrund Zur sichtbarmachung von Fehlstellen und Schleifriefen / Struktur Kontrollpulver (3M) Läufer im Primer / Rauhe stellen verwenden. Läufer im Material gesondert vor dem eigentlichen Schliff beseitigen.
Schmutzeinschlüsse Kein grobes Schleifpapier verwenden (schliff mit P400 / P500)
Alle Ecken und Kanten gut anschleifen.
Nach demSchleifen Karosse innen und Aussen Staubfrei machen und gründlich
Reinigen. Nach Abkleben Karosse nocheinmal einigen.Abschließend genau auf Fehler kontrollieren und Fehler beseitigen.
Alle Arbeitsschritte Dokumentieren. Prüfung Wahreneingang Preparation Area, before
Primerapplikation Preparation Area, Paint technician Preparation, before painting
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Page 914 of 1173
Automobili LamborghiniITALIANOAction plan verniciatore:Soggetto: Qualità, Verniciatura, FinizioneStand: 24.08.05
ResponsabileSoggettoErrori possibiliMisure preventiveArea
ConsegnaVetture sporcheControllare le scocche alla consegna per i danni e coprirleScocca completa EDP aggiunte, sporche, segni di carteggiatura, coperte Controllare EDP per segni di carteggiatura, sporchi, inclusioni, runouts, punti di ruggine
EDP runouts e depositi EDP sul telaio; corrosioni Controllare le parti in carbonio, per graffi, porosità, ammaccature, buchi, riparazioni
Porosità sulle parti in carbonio Controllo di zone di ripristino
Carbonio visibile (angoli carteggiati, ecc.) Controllo parti in acciaio per danni, ammaccature, graffi, segni di carteggiatura, bordi
EP-aggiunte di fondo, riparati, con difetti Controllare EP-fondo per buona superficie e senza difettosità
Difetti del sottostrato, buchi, parti d'acciaio difettose Decidere quali difetti possono essere riparati senza sforzi eccessivi
perché urtate, ammaccature, graffi, segi di carteggiatu- Annotare i difetti su una "scheda scocca"ra sulle parti Informare i fornitori e Lamborghini sui difetti riscontrati
Adeguato sealing della scocca Per grossi danneggiamenti, decidere con Lamborghini come gestire la rimozione della
anomaliaPreparazione particolariDifetti sopra e sotto EDP non riparatiPrima di cominciare a lavorare, pulire completamente la scoccaParti in acciaioPorosità in zone di ripristinoRilevare i difetti dentro e sopra l'EDP e nel sottostrato, ripararli completamente
Segni di carteggiatura visibili in superficie Se ci sono grossi danni, informare Lamborghini ed i fornitori
Adesione di vernice sui bordi e sugli angoli Rilevare i difetti sopra e nelle parti in carbonio, ripararle completamente Se ci sono grossi danni, informare Lamborghini ed i fornitori
Parti in carbonio Pororsità del carbonio, Tenere le aree di ripristino il più piccole possibili, carteggiando al minimo il film di costruzione
Contatto non sufficiente fra EP-fondo ed il carbonio, Evitare porosità nel carteggiare le superfici, segni di massima, carteggiare alla fine con una
graffi, cavità, buchi, carbonio aperto, grana più fine (es: P80, P120, P180, P240), utilizzare la polvere di controllo (3M)
Carteggiando la superficie sotto il EP-fondo, aggiunte di Carteggiare tutte le zone, angoli, bordi con una carta fine (P240)
EP-fondo, con zone riparate, carbonio visibile Carteggiare tutti i bordi e gli angoli completamente (3M Sanding Pad) Non toccare il metallo con le mani nude, lavare le zone di metallo con wash primer
Carteggiare le parti in carbonio dopo la carteggiatura del EP-fondo prima dell'applicazione delPU-fondo. Non carteggiare ancora le parti in carbonio!
Prima del PU-fondo / Applicare il Wash-primer sul tutta la superficie, sgrassare e lasciareasciugare
Controllare per eventuali difettosità e ripararle come ultima fase
Documentare tutte le azioni in una "scheda scocca"
Preparazione scoccaFondo errato o materiale erratoScegliere il materiale per il fondo a seconda della superficie (Metallo / Carbonio)Prima revisione Mixup dei singoli componenti del fondo Preparare il fondo seguendo le schede tecnichePreparazione del mix dei materiali non a procedura Non eccedere i tempi di scadenza e di apertura dei prodotti
Data di scadenza dei materiali superata Controllare il film di costruzione, non eccedere il livello massimo
Superficie non propriamente pulita / polverosa Mantenere i tempi di flash-off fra le applicazioni, come specificato, non accorciarli o allungarli!
Temperatura di essiccazione troppo bassa / troppo alta Mantenere i tempi di essiccazione e le temperature di essiccazione
Temperatura di cottura troppo bassa / troppo alta Controllare che la superficie sia pulita prima dell'applicazione del fondo
Film di costruzione troppo basso / troppo alto Effettuare un controllo finale per difettosità, riparare i difetti
Tempo di flash-off non a procedura Documentare tutte le azioni in una "scheda scocca"
Preparazione scoccaPorosità nel sottostratoTrovare tutte le porosità e chiuderle prima di carteggiareSeconda revisione Segni di carteggiatura ancora visibili nel sottostrato Per rendere più visibili i difetti ed i segni di carteggiatura utilizzare la polvere di struttura (3M)runouts nel fondo / zone rovinate Carteggiare runouts dal materiale separatamente dalla fase di carteggiatura
Inclusioni di sporco Non usare carte con grana di massima (carteggiare con P400 / P500)
Carteggiare i bordi e gli angoli adeguatamente
Eliminare la polvere dalla scocca dopo averla carteggiata, dentro e fuori, lavarla completa-
mente. Dopo averla mascherata, pulirla di nuovoEffettuare un controllo finale per difettosità, riparare i difetti
Documentare tutte le azioni in una "scheda scocca" Controllo Qualità in
accettazione
Prima revisione (prima
dell'applicazione del fondo)
Prima revisione
(applicazione del fondo)
Preparazione, prima
della verniciatura
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Page 916 of 1173
Automobili LamborghiniENGLISHAction plan paint shop: All Paint shop'sSubject: Quality, Painting, FinishStand: 08.08.05
ResponsibleSubjectPossible mistakesPreventive MeasureArea
DeliveryDirty carbodiesCheck carbodies at delivery for damage, cover carbodyCompleted Body EDP rough, dirty, sandmarks, overcoated Check EDP for sandmarks, dirt, inclusions, runouts, rust spots, measure filmbuild
EDP runouts and EDP deposits on frame; corrosion Check carbon parts for free visible carbon, scratches, pores, dents, holes, repaired areas
Porosity on carbon parts Check stopped areas
free visible carbon (sanded edges etc.) Check steel parts for damage, dents, scratches, sandmarks, edges
EP-primer rough, repaired, with defects Check EP-primer for good surface and no defects
defects from substrate, holes, dents Decide which defects can be repaired without excessive efforts
steel parts with bumps, dents, scratches, sandmarks Record Defects on a "car body sheet"scratches on parts Inform suppliers and Lamborghini about defects
proper sealing of carbody For gross damage, decide with Lamborghini how to handle removal of damage
Preparationdefects in and below EDP not repairedbefore start of work, clean car body thoroughly.Steel parts porosity on stopped parts detect defects in and on EDP and on metal substrate, repair completely visible sandmarks on surface If gross damage, inform Lamborghini and suppliers
bad paint adhesion at edges and corners detect defects in and on carbon parts, repair completely If gross damage, inform Lamborghini and suppliers
Carbon parts porosity from carbon, Keep stopped areas as small as possible, keep sanding surfacer filmbuild low
no sufficient contact between EP-primer and carbon Avoid pores in sanding surfacer, no coarse sandmarks, final sanding fine
scratches, cavities, holes, open carbon, (eg: P80, P120, P180, P240), use control dust (3M).
sanding surfacer under EP-primer, EP-primer rough with Sand all areas, corners, edges fine (P240)
repaired areas, free visible carbon fibers Sand all edges and corners thoroughly (3M Sanding Pad) Don't touch bare metal with naked hands, primer metal with wash primer
Sand bare carbon areas after sanding with EP-primer before application of PU-primerDo not sand through to bare carbon again!
before PU-primer / Wash-primer application clear surface very good, degrease and let dryCheck for defects and repair them as final stepDocument all your actions to this stage
PreparationWrong primer on wrong materialChoose primer material according to substrate (Metal / Carbon)Primer Application Mixup of single primer components Make primer preparation according to technical datasheetPreparation of material mix not according to procedure Do not exceed shelf life and open time
shelf life of material exceeded Watch film builds, do not exceed maximum filmbuild
surface not properly cleaned / dusty Keep flash-off time between coatings within spec, do not shorten or lenghten!
drying temperature too low / too high Keep drying times and drying temperatures
baking temperature too low / too high Check if surface is cleaned before primer application
film build too low / too high Make final check for defects, repair defects
flash-off time not according to procedure Document all your actions to this stage
PreparationPores from substrateFind all pores and fill before sandingPrimer sanding / grinding still visible sandmarks from substrate To make defects and sandmarks visible: use structure control dust (3M)runouts in primer / rough areas Sand runouts from the material separate from the sanding step. dirt inclusions Do not use coarse sandpaper (sand with P400 / P500)
Sand all edges and corners properlyDe-dust carbody after sanding from inside and outside and clean thoroughlyAfter masking, clean car body again.Make final check for defects, repair defectsDocument all your actions to this stage
Quality Control ReceivingGoods Preparation Area, before Primer Application Preparation Area, Paint technician Preparation, before painting
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Page 923 of 1173
Copyright by PPG Industries Lacke GmbH Autor: Franco BusiaGrafik: Mike Rohde
Page 6Origin of blistering
EP - PrimerKlarlack
Carbonschicht
Trennmittelrückstände Lösemittelrückstände
Residues of salt
Porosity Oder andere Substrate
Blistering can create by:
Porosity by basic material,
Incorrect production of Carbon- parts,
Improper handling prior to production,
Residue deposits of pollution by the pre-production processes,
Solvents beneat the finish,
humidity by salt residues on the surface,
Improper cleaning of the surface
delamination
Dust,
impuritiespore
Clearcoat
Epoxid- primer
Residues of solvent
Carbonfiber or
other surface
Separating material
on behalf of Lamborghini S.p.A.
Page 926 of 1173
Copyright by PPG Industries Lacke GmbH Autor: Franco BusiaGrafik: Mike Rohde
Technical manual of reworkPage 9
Before you start with the rework,
read carefuly the
Safety Instruktions and Technical Data sheets!
For all activity respect the Safety Instructions and Technical D ata sheets, Page 19+
on behalf of Lamborghini S.p.A.
Page 980 of 1173
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® 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
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The LIE system is a system that integrates a digital electronic ignition spark advance and static timing system with an electronic indirect fuel injection system of the multiple timed sequential type.
According to the engine structure, which has the cylinders divided into two cylinder banks, two complete systems that
are suitably synchronized with each other have been applied, and each controls a cylinder bank of six cylinders. As
a consequence there are two engine control units, connected to each other by the CAN line, managing the injection
and ignition of each cylinder bank and four throttle bodies connected to each other by CAN lines and electronically
controlled by LIE control units through the ETB control units. These control units are also connected by the CAN line
to the GFA control unit that co-ordinates and manages many functions especially concerning diagnostic. The system can be divided into the following sub-systems: ELECTRICAL/ELECTRONIC SYSTEM
FUEL SUPPLY SYSTEM
INTAKE SYSTEM
THROTTLE BODIES GENERAL DESCRIPTION
EXHAUST SYSTEM
ANTI-EVAPORATION DEVICES The system can properly acquire the following parameters: •Engine speed;
• Correct TDC sequence of the cylinders (injection timing);
• Absolute pressure in the intake manifold;
• Throttle position and position variation;
• Accelerator pedal position;
• Intake air temperature;
• Engine coolant temperature;
• Exhaust gas internal temperature;
• Mixture strength;
• Battery voltage;
• Possible start-up of air conditioner;
• Pressure in the exhaust manifold;
• Pressure in the fuel anti-evaporative circuit.
Page 981 of 1173
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® 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
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$ F F H O H U D W R U 3 H G D O 3 R V L W L R Q 6 H Q V R U V 3 3 6
The accelerator pedal position sensors are two potentiometers both coaxially installed in the same casing and activated by the accelerator pedal by means of a shaft.
The accelerator pedal angle position is detected by the two coaxial potentiometers: The signal is sent to
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units and then to ( 7 % F R Q W U R O X Q L W V (one per cylinder bank), which in turn control the respective throttle bodies.
$ F F H O H U D W R U S H G D O S R V L W L R Q V H Q V R U F R Q Q H F W L R Q G L D J U D P ) L J
A. Accelerator pedal position sensors
% Cable
C. ECU (cylinder bank 1-6)
' ECU (cylinder bank 7-12)
( CAN connection at low speed
) Cylinder bank 1-6 throttle bodies
G. Cylinder bank 7-12 throttle bodies
H. ETB