Ford 5C2S-19A268-AA User Manual

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DO NOT DESTROY: THIS MANUAL IS REQUIRED BY LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER.

2005

E-SERIES

INCOMPLETE VEHICLE MANUAL

Incomplete Vehicle Types

For This Manual

INCOMPLETE E-SERIES VANS &

WAGONS

E-SERIES CUTAWAY

E-SERIES BASIC CHASSIS

May, 2004

5C2S-19A268-AA

U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS

(APPLICATION BY VEHICLE TYPE)

Bus (Not Truck Truck Standard School School (Not (Walk-in (1)

Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.

101 Control Location, Identication and Illumination X X X X X 102 Transmission Shift Lever Sequence, Starter

Interlock & Transmission Braking Effect X X X X X 103 Windshield Defrosting & Defogging Systems X X X X X 104 Windshield Wiping and Washing Systems X X X X X 105 Hydraulic and Electric Brake Systems X X X X X 106 Brake Hoses X X X X X X 108 Lamps, Reective Devices & Associated Equipment X X X X X X

108.1 Headlamps (Canada only) X X X X X X 110 Tire Selection and Rims (U.S. only) X X X X X X 111 Rearview Mirrors X X X X X 113 Hood Latch Systems X X X X X 114 Theft Protection X(2) X(2) 115 Vehicle Identication Number (Canada only) X X X X X 116 Hydraulic Brake Fluids X X X X X X 118 Power Operated Window, Partition, and Roof

Panel Systems X(2) X(2) X(2) 119 New Pneumatic Tires for Vehicles Other

Than Passenger Cars X 120 Tire Selection and Rims for Motor Vehicles

Other Than Passenger Cars X X X X X X 124 Accelerator Control Systems X X X X X 131 School Bus Pedestrian Safety Devices (except

Multifunction School Activity Bus) X 135 Light Vehicle Brake Systems X(10) X(10) X(10) X(10) X(10) 201 Occupant Protection in Interior Impact X(2)(9) X(2)(9) X(2) X(2) X(2)(9) 202 Head Restraints X(2) X(2) X(2) X(2) X(2) 203 Impact Protection for the Driver from the

Steering Control System X(2) X(2) X(2) X(2) 204 Steering Control Rearward Displacement X(3) X(3) X(3) X(3) 205 Glazing Materials X X X X X X 206 Door Locks and Door Retention Components X X X 207 Seating System X X X X X 208 Occupant Crash Protection X(5)(6) X(5)(6) X(5)(6) X(5)(6) X(5)(6) X 209 Seat Belt Assemblies X X X X 210 Seat Belt Assembly Anchorages X X X X X

210.1 User-Ready Tether Anchorages for Restraint Systems (Canada only) X X X X

210.2 Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions (Canada only) X X X X

212 Windshield Mounting X(2) X(2) X(2) X(2) 213 Child Restraint Systems X X X X X X 214 Side Impact Protection X(2)(7) X(2) X(2)(7) X(2)(7) 217 Bus Window Retention and Release X X 219 Windshield Zone Intrusion X(2) X(2) X(2) X(2)

(Continued on Page 1)

E-SERIES (May, 2004)

U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS

(APPLICATION BY VEHICLE TYPE)

(Continued from Inside Front Cover)

Bus (Not Truck Truck Standard School School (Not (Walk-in (1)

Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.

220 School Bus Rollover Protection X 221 School Bus Body Joint Strength X 222 School Bus Passenger Seating and Crash

Protection X 225 Child Restraint Anchorage Systems (U.S. only) X(8) X(8) X(8) X(8) X(8) 301 Fuel System Integrity X(2) X X(2) X(2) X(2) 302 Flammability of Interior Materials X X X X X PART Vehicle Identication Number (U.S. only) X X X X X

565.4 1106 Noise Emissions (Canada only) X X X X X

(1) Applicable to Equipment for use on applicable vehicle types.

(2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb]

or less.

(3) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb]

or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less.

(4) Applicable to vehicles with a GVWR of 2722 kg [6000 lb] or

less.

(5) Injury criteria required for vehicles with a GVWR of 3856 kg

[8500 lb] or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less except, in U.S., walk-in van-type trucks and vehicles designed to be sold exclusively to the U.S. Postal Service and, in Canada, vehicles manufactured for operation by persons with disabilities.

(6) Injury criteria is optional for some vehicles where not required.

(7) Dynamic Performance Requirements apply to MPV, truck or a

bus with a GVWR of 2722 kg [6000 lb] or less.

(8) Tether anchors and latch/ISO Fix lower anchors that are installed

voluntarily or by regulation must comply with this Standard.

(9) The requirements of section S6 of Standard Number 201 (United

States) do not apply to buses with a GVWR more than 3860 kg [8510 lb] and walk-in van type trucks.

(10) Applicable to vehicles with a GVWR of 3500 kg [7716 lb] or

less.

E-SERIES (May, 2004) 1

E-SERIES (May, 2004) 3

INTRODUCTION

Information in this manual is furnished pursuant to United States and Canadian safety regulations or, in some cases where the information is not required by regulation, is furnished for the convenience of intermediate or nal stage vehicle manufacturers. Incomplete vehicles manufactured for sale or importation into the U.S., are specially equipped for the United States. The descriptions and statements contained in the manual relate only to motor vehicle safety standards issued under the National Trafc and Motor Vehicle Safety Act of 1966 as amended.

An incomplete vehicle manufactured for sale or importation into Canada is specially equipped for Canada. This vehicle conforms to the applicable Canadian Motor Vehicle Safety Standards (CMVSS) on the date of manufacture printed on the cover of this manual. Requirements unique to vehicles for use in Canada are identied in the Statements of Conformity and the “Canadian Vehicles”, page 48.

The Emission Certication Information section of this manual contains information regarding conformity to exhaust emission regulations of the United States, Canada, and the State of California and fuel economy regulations of the United States.

This manual should not be relied upon with respect to compliance with any regulation of the Federal Highway Administration or regulations issued pursuant to the Occupational Safety and Health Act (OSHA) or any other federal, state, or local regulations governing the performance or construction of motor vehicles (except for those requirements shown under the headings “Unleaded Gasoline Label,” page 49, “Warranty and Maintenance,” page 50, and “Emission Control Information Label,” page 50). It is the responsibility of the nal stage manufacturer to determine applicability and comply with any federal, state, or local requirements not detailed in this manual.

IMPORTANT:

UNITED STATES VEHICLES

Ford Motor Company has endeavored, whenever possible, to state the specific conditions under which an incomplete vehicle may be completed to conform to each applicable Federal Motor Vehicle Safety Standard. These specic statements are intended to aid subsequent stage manufacturers in avoiding instances of inadvertent noncompliance to particular standards.

Note that the nal responsibility for the compliance of the completed vehicle rests with the nal stage manufacturer who is required by law to certify, as prescribed by Section

567.5 of Title 49, Code of Federal Regulations, that the completed vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and that all applicable federal, state and California emission/noise standards are conformed with.

Ford Motor Company does not make any representation as to the appropriateness of modications for any particular application other than expressly stated herein. Intermediate and nal stage manufacturers must exercise proper engineering judgment to determine if a modication is appropriate for their specic application.

IMPORTANT:

UNITED STATES AND CANADIAN VEHICLES

Alterations to an incomplete vehicle by someone other than Ford Motor Company, or damage in transit, may affect compliance statements that are furnished in this manual, or representations that are printed on the label that may be afxed to a vehicle.

INTRODUCTION

E-SERIES (May, 2004)2

TABLE OF CONTENTS

DEFINITIONS .................................................................................... 4-5

GENERAL INFORMATION .................................................................... 6

Directions........................................................................................... 6

VEHICLE DESCRIPTION ..................................................................... 7

COMPLETED VEHICLE TYPES .............................................................8

STATEMENTS OF CONFORMITY................................................... 9-47

CANADIAN VEHICLES

Vehicle Identication ........................................................................ 48

Daytime Running Lamp (DRL)......................................................... 48

Canadian Radio Frequency Interference (RFI)................................ 48

EMISSION CERTIFICATION INFORMATION

Medium Duty Passenger Vehicles (MDPV).......................................49

Frontal Area and Weight Restrictions ...............................................49

High Altitude Requirements..............................................................49

Emission Control Hardware ..............................................................49

Unleaded Gasoline Label ................................................................ 49

Exterior Noise .................................................................................. 50

Tampering with Noise Controls .........................................................50

Warranty and Maintenance.............................................................. 50

Evaporative Emissions..................................................................... 50

Malfunction Indicator Light (MIL) ..................................................... 50

Ozone Depleting Substance (ODS)..................................................50

Emission Control Information Label................................................. 50

California Fuel Vapor Recovery ....................................................... 51

California Motor Vehicle Emission Control Label ............................. 51

Radio Frequency Interference (RFI) ................................................ 51

SUPPLEMENTS .................................................................................. 52

REFERENCE INFORMATION ............................................. Back Cover

E-SERIES (May, 2004) 3

TABLE OF CONTENTS

DEFINITIONS

The following denitions are from Title 49, Code of Federal Regulations, Parts 567.3, 568.3 and 571.3 where noted. Canadian denitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company denitions are for the purpose of this manual only. Some terms are followed by an abbreviation that is used throughout this manual.

Ambulance – is a vehicle for emergency medical care which

provides: A driver’s compartment; a patient compartment to accommodate an Emergency Medical Technician (EMT), Paramedic, and two litter patients (one patient on the primary cot and secondary patient on folding litter located on the squad bench) so positioned that the primary patient can be given intensive life-support during transit; equipment and supplies for emergency care at the scene as well as during transport; two-way radio communication; and, when necessary, equipment for light rescue/extrication procedures. The Ambulance shall be designed and constructed to afford safety, comfort, and avoid aggravation of the patient’s injury or illness. (From Federal Specication KKK-A-1822-E). Ford Motor Company also includes within its denition of ambulance any vehicle that is used for transporting life-support equipment, for rescue operations, or for nonemergency patient transfer if the engine of the vehicle is equipped with a “throttle kicker” device, which enables an operator to increase engine speed over normal idle speed when the vehicle is not moving.

B-Pillar – is the vehicle body structure located directly

rearward of each front door. This structure will include the outer panel, all inner panels or reinforcements which support the door opening, the door latching system, and/or the roof structure. (Ford Motor Company)

Basic (Stripped) Chassis – an incomplete vehicle, without

occupant compartment, that requires the addition of an occu pant compartment and cargo-carrying, work performing, or load-bearing components to perform its intended function. (Ford Motor Company)

Bu s – a motor veh icle with motive po wer, exce pt a

trailer, designed for carr ying more than 10 persons. (49CFR571.3)

Bus (Canada) – a vehicle having a designated seating capacity

of more than 10, but does not include a trailer or a vehicle imported temporarily for special purposes. (autobus)

Chassis Cab – an incomplete vehicle, with completed occupant

compartment, that requires only the addition of cargocarrying, work performing, or load-bearing components to perform its intended functions. (49CFR567.3)

Completed Vehicle – a vehicle that requires no further

manufacturing operations to perform its intended function, other than the addition of readily attachable components, such as mirrors or tire and rim assemblies, or minor nishing operations such as painting. (49CFR568.3)

Critical Control Item – is a component or procedure which

may affect compliance with a federal regulation or, which could directly affect the safe operation of the vehicle. The identifying symbol is an inverted delta ( ). (Ford Motor Company)

Cutaway Chassis – an incomplete vehicle that has the back

of the cab cut out for the intended installation of a structure that permits access from the driver’s area to the back of the completed vehicle. (Ford Motor Company)

Cutaway Chassis (Canada) – an incomplete vehicle that has

the back of the cab cut out for the intended installation of a structure that permits access from the driver’s area to the back of the vehicle. (châssis tronqué)

Designated Seating Position – any plan view location

capable of accommodating a person at least as large as a 5th percentile adult female, if the overall seat conguration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion, except for auxiliary seating accommodations such as temporary or folding jump seats. Any bench or split-bench seat in passenger car, truck, or multipurpose passenger vehicle with a GVWR less than 4,536 kilograms (10,000 pounds), or having greater than 50 inches of hip room (measured in accordance with SAE Standard J1100(a)) shall have not less than three designated seating positions, unless the seat design or vehicle design is such that the center position cannot be used for seating. (49CFR571.3) (abbreviated by Ford Motor Company)

Designated Seating Position (Canada) – any plan view

position capable of accommodating a person at least as large as a 5th percentile adult female, as dened in section 100 of Schedule IV, where the overall seat conguration and design and the vehicle design are such that the position is likely to be used as a seating position while the vehicle is in motion, but does not include any plan view position of temporary or folding jump seats or other auxiliary seating accommodation. (place assise désignée)

Final-Stage Manufacturer – a person who performs such

manufacturing operations on an incomplete vehicle that it becomes a completed vehicle. (49CFR568.3)

Gross Axle Weight Rating (GAWR) – the value specied

by the vehicle manufacturer as the load-carrying capacity of a single axle system, as measured at the tire-ground interfaces. (49CFR571.3)

Gross Combination Weight Rating (GCWR) – the value

specied by the manufacturer as the loaded weight of a combination vehicle. (49CFR571.3)

Gross Vehicle Weight Rating (GVWR) – the value specied

by the manufacturer as the loaded weight of a single vehicle. (49CFR571.3)

H-Point – the mechanically hinged hip point of a manikin

which simulates the actual pivot center of the human torso and thigh, described in SAE Recommended Practice J826, “Manikins For Use in Defining Vehicle Seating Accommodations,” November 1962. (49CFR571.3)

H-point (Canada) – the mechanically hinged hip point of a

manikin that simulates the actual pivot centre of the human torso and thigh, described in SAE Standard J826 APR80, Devices for Use in Dening and Measuring Vehicle Seating Accommodation. (point H)

Incomplete Vehicle – an assemblage consisting, as a

minimum, of frame and chassis structure, power train, steering system, suspension system, and braking system, to the extent that those systems are to be part of the completed vehicle, that requires further manufacturing operations, other than the addition of readily attachable components such as mirrors or tire and rim assemblies, or minor nishing operations, such as painting, to become a completed vehicle. (49CFR568.3)

DEFINITIONS

E-SERIES (May, 2004)4 E-SERIES (May, 2004) 5

Incomplete Vehicle (Canada) – a vehicle (a) other than a

vehicle imported temporarily for special purposes, that is capable of being driven and that consists, at a minimum, of a chassis structure, power train, steering system, suspension system and braking system in the state in which those systems are to be par t of the completed vehicle, but requires further manufacturing operations to become a completed vehicle or (b) that is an incomplete trailer. (véhicule incomplet)

In com plete Veh icle Manu fac tur er – a pe rso n wh o

manufactures a n incomplet e vehi cle by a ssembling components none of which, taken separately, constitute an incomplete vehicle. (49CFR568.3)

Intermediate Manufacturer – a person, other than the

in compl ete veh icle man ufactur er or the final st age manufacturer, who performs manufacturing operations on an incomplete vehicle. (49CFR568.3)

Motor Home – a multi-purpose vehicle with motive power that is

designed to provide temporary residential accommodations, as evidenced by the presence of at least four of the following facilities: Cooking; refrigeration or ice box; selfcontained toilet; heating and/or air conditioning; a potable water supply system including a faucet and a sink; and a separate 110-125 volt electrical power supply and/or an LP gas supply. (49CFR571.3)

Multifunction School Activity Bus (MFSAB) – a school bus

whose purposes do not include transporting students to and from home or school bus stops. (49CFR571.3)

Multipurpose Passenger Vehicle (MPV) – a motor vehicle

with motive power, except a low-speed vehicle or trailer, designed to carry 10 persons or less which is constructed either on a truck chassis or with special features for occasional off-road operation. (49CFR571.3)

Multipurpose Passenger Vehicle (MPV) (Canada) – a vehicle

having a designated seating capacity of 10 or less that is constructed either on a truck-chassis or with special features for occasional off-road operation, but does not include an air cushion vehicle, an all-terrain vehicle, a golf cart, a lowspeed vehicle, a passenger car, a truck or a vehicle imported temporarily for special purposes. (véhicule de tourisme à usages multiples)

School Bus – a bus that is sold, or introduced in interstate

commerce, for purposes that include carrying students to and from school or related events, but does not include a bus designed and sold for operation as a common carrier in urban transportation. (49CFR571.3)

School Bus (Canada) – a bus designed or equipped primarily

to carry students to and from school. (autobus scolaire)

Seating Reference Point – the unique design H-point, as

dened in SAE J1100 (June 1984), which (abbreviated by Ford Motor Company):

(a) Establishes the rearmost normal design driving or

riding position of each designated seating position in a vehicle;

(b) Has X, Y, and Z coordinates established relative to the

designed vehicle structure;

torso and thigh; and

(d) Is the reference point employed to position the two-

dimensional drafting template described in SAE J826 (May 1987).

Seating Reference Point (Canada) – the unique Design H-

point, as dened in section 2.2.11.1 of SAE Recommended Practice J1100 (June 1993), that

(a) establishes the rearmost normal design driving or riding

position of each designated seating position, taking into account all modes of adjustment – horizontal, vertical and tilt – in a vehicle,

(b) has X, Y and Z coordinates, as defined in section

2.2.3 of SAE Recommended Practice J1100 (June

1993), established relative to the designed vehicle structure,

torso and thigh, and

(d) is the reference point employed to position the H-point

template with the 95th percentile leg, as described in section 3.1 of SAE Standard J826 (June 1992), or, if that drafting template cannot be positioned, the reference point when the seat is in its rearmost adjustment position. (point de référence de position assise)

Second Unit Body (SUB) – consists of the body structure

and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle. (Ford Motor Company)

Subsequent Stage Manufacturer – a term which means

either intermediate or nal stage manufacturers or both. (Ford Motor Company)

Trimmed Seat – a complete functional seat assembly including

the seat pedestal, seat track, seat base frame, seat back, recliner mechanism, seat padding, all attaching hardware, and the nal trim material (i.e., cloth, leather, or vinyl). (Ford Motor Company)

Truck – a motor vehicle with motive power, except a trailer,

designed primarily for the transportation of property or special purpose equipment. (49CFR571.3)

Truck (Canada) – a vehicle designed pr imarily for the

transportation of property or special-purpose equipment but does not include a competition vehicle, a crawlermounted vehicle, a trailer, a work vehicle, a vehicle imported temporarily for special purposes or a vehicle designed for operation exclusively off-road. (camion)

Unloaded Vehicle Weight (UVW) – the weight of a vehicle

with maximum capacity of all uids necessary for operation of the vehicle, but without cargo, occupants, or accessories that are ordinarily removed from the vehicle when it is not in use. (49CFR571.3)

Unloaded Vehicle Weight (Canada) – the weight of a vehicle

equipped with the containers for the uids necessary for the operation of the vehicle lled to their maximum capacity, but without cargo or occupants. (poids du véhicule sans charge)

Untrimmed Seat – the structure including the seat pedestal,

seat track, seat base frame, seat back, recliner mechanism, seat padding, and all attaching hardware required for a functional seat assembly without the nal trim material (e.g., cloth, leather, or vinyl) and trim material attaching components. (Ford Motor Company)

Walk-In Van – a step entry city delivery van type vehicle that

permits a person to enter the vehicle without stooping. This denition by Ford Motor Company is based on information appearing in 41 FR 54945, published December 16,1976, and in 42 FR 34288, published July 5,1977.

Walk-In Van (Canada) – a van type of truck in which a person

having a height of 1700 mm can enter the occupant compartment in an upright position by a front door. (fourgon à accès en position debout)

E-SERIES (May, 2004) 5

DEFINITIONS

E-SERIES (May, 2004) 7

GENERAL INFORMATION

Information in this section is provided pursuant to Part 568 of Title 49, Code of Federal Regulations. “Vehicles Manufactured in Two or More Stages.” Part 568 species that nal stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards, and Section 6 of the Canadian Motor Vehicle Safety Regulations (CMVSR), Vehicles Manufactured in Stages. Section 6.6 of the CMVSR provides labeling requirements for vehicles that are to be sold in Canada.

DIRECTIONS

STATEMENTS OF CONFORMITY

The Statements of Conformity section, which begin on page 9 of this manual, lists the Federal Motor Vehicle Safety Standards in effect on the date of manufacture of this incomplete vehicle that are applicable to the type(s) of completed vehicles into which this incomplete vehicle may be manufactured. This date is shown on the label afxed to the cover of this manual. These statements, in most cases, apply to specic types of incomplete or completed vehicles and identify GVWR and UVW weight ranges.

The incomplete vehicle type is identied by the 5th, 6th, and 7th digits of the Vehicle Identification Number (VIN); see page 7. The completed vehicle types to which this incomplete vehicle may appropriately be completed is printed on the label, under the heading “May Be Completed As,” that is afxed to the cover of this document. The Completed Vehicle Types charts on page 8 identies how various incomplete vehicles with an Optional Prep Packages or a Trim Code, may be completed.

Each statement of conformity is identied by a safety standard number located at the left margin. Because there may be multiple statements of conformity for each safety standard, use care to select the appropriate statement. Unique CMVSS requirements will be identified at the conclusion of the representations for a particular safety standard.

Compliance statements provided in this manual are of the three following types:

Type I • A statement that the vehicle, when completed,

will conform to the standard if no alterations are made in identied components of the incomplete vehicle.

Type II • A sta tem ent of specific conditio ns of fi nal

manufacture under which the incomplete vehicle manufacturer species that the completed vehicle will conform to the standard.

Type III • A statement of conformity with the standard is

not substantially affected by the design of the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard.

IMPORTANT:

To rely on the compliance representations in this manual, the incomplete vehicles must be completed as one of the completed vehicle types designated on the label afxed to the cover of this manual, and must not exceed the specied GVWR, GAWRs, or the Unloaded Vehicle Weight limits when specied in this manual.

VEHICLE SPECIAL ORDER (VSO) VEHICLES

VSO vehicles can be identied by a six digit number with the letters VSO below the digits in the lower right corner of the Incomplete Vehicle Label which is afxed to the driver-door lock pillar. See the sample label on page 7.

The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles. These vehicles are identied in the charts on page 8. Other VSO vehicles may require additional Statements of Conformity which will be in the Supplement Section of this manual.

FORD TRUCK ASSISTANCE

Throughout this manual you will nd references to information found in the Ford Truck Body Builders Layout Book. Additional Design Recommendations and specications are also provided to assist subsequent stage manufacturers in completing incomplete vehicles. To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM’s or books please visit our website at www.eet.ford.com/truckbbas. Under Publications select Body Builders Order Forms. All dealer requests can be handled online. All other U.S. orders should be faxed to (734) 713-2971. Canadian orders should be faxed to (905) 670-0844.

The Ford Truck Body Builder Advisory Ser vice may be consulted regarding information contained in this manual.

• Call (877) 840-4338

• Fax (313) 594-2633

• E-Mai l bbasqa@ ford .com or a t the BBA S website – www.eet.ford.com/truckbbas

Include your name, company and telephone number with all inquiries. If requesting written materials or CD-ROM, include your mailing address.

GENERAL INFORMATION

E-SERIES (May, 2004)6

VEHICLE DESCRIPTION

The cover of this manual identifies the three incomplete

vehicle con gurations for which compliance representations

for the speci c vehicle to which this manual belongs. The label

vehicle with the corresponding VIN.

The GVWR

The front and rear GAWRs

Tire and wheel size

vehicle may be manufactured

All E-Series incomplete vehicles manufactured by Ford Motor

The 5th, 6th, and 7th digits of the Vehicle Identification

three digits are used in the Completed Vehicle Types charts

the VIN on the incomplete vehicle label, when provided, will

The Canadian Motor Vehicle Safety Act and Regulations

with the National Safety mark on it on vehicles manufactured

for sale in Canada. A label representative of those installed by

vehicle type charts on page 8 will identify incomplete vehicles

wish to rely on the Statements of Conformity or, in some cases,

vehicle and the label on the front of this manual will identify

the prep package.

INCOMPLETE VEHICLE MANUFACTURED BY

FORD MOTOR COMPANY

MADE IN U.S.A.

GVWR:

FRONT GAWR

VIN

PSI COLD

WITH TIRES RIMS

REAR GAWR

EXTERIOR PAINT COLORS

TYPEGVW

BODY

TRANS

AXLE

TAPE

SPRINGS

161

F379

AJ8

E 6

N Y

4200LB 1905KG LT215/85R16D 16X6K

11000LB/4989KG

8250LB 3742KG LT215/85R16D 16X6K

DUAL

F85B1520472AB

TYPICAL E-SERIES - U.S.

TYPICAL E-SERIES - CANADA

VSO

410047

BAR CODE V.I.N (CALIFORNIA

)

VSO VEHICLE

DATE OF MANUFACTURE

VEHICLE TYPE (SEE CHART ON PAGE 8)

OPTIONAL PREP PACKAGE

VSO VEHICLE

DATE OF MANUFACTURE

VEHICLE TYPE (SEE CHART ON PAGE 8)

01/05

DATE

01/05

DATE

1FDKE37HZ5HA24638

EQUIPPED WITH THE FORD AMBULANCE PREP PKG.

VSO

1019

1FDKE37HZ5HA24639

E-SERIES (May, 2004) 9

COMPLETED VEHICLE TYPES

COMPLETED VEHICLES

5TH, 6TH, 7TH

VIN DIGIT

E-Series

E11 Incomplete E-150 Wagon X 6 E14 Incomplete E-150 Regular Van X 5 E24 Incomplete E-250 Regular Van X 5 E31 Incomplete E-350 Super Duty Wagon X 6 6 E34 Incomplete E-350 Super Duty Regular Van X 5 1 E35 E-350 Super Duty Cutaway X 3 1 4 2 E39 E-350 Super Duty Basic (Stripped) Chassis X E45 E-450 Super Duty Cutaway X 3 1 4 2 E49 E-450 Super Duty Basic (Stripped) Chassis X S24 Incomplete E-250 Extended Van X 5 S31 Incomplete E-350 Super Duty Extended Wagon X 6 6 S34 Incomplete E-350 Super Duty Extended Van X 5 1 5

IMPORTANT: Ford Motor Company makes no representation that the completed vehicle types listed above are the only vehicle types appropriate for the incomplete vehicles listed. However, if a unit is completed as a vehicle type other than as listed above, the Statements of Conformity may not be applicable.

INCOMPLETE VEHICLES

(1) Ambulance Prep Package

(2) School Bus Prep Package

- E-350 available on 9600 lb GVWR Single Rear Wheels (SRW), and 11,500 lb GVWR Dual Rear Wheels (DRW) only

(3) Motorhome Prep Package

(4) Shuttle Bus Prep Package

(5) Recreational Van

(6) Center Aisle Seat Prep Package

TRUCK

(WALK-IN VAN)

MPV

(AMBULANCE)

BUS (NOT

SCHOOL BUS)

SCHOOL BUS

COMPLETED VEHICLE TYPES

E-SERIES (May, 2004)8

STATEMENTS OF CONFORMITY

The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States or Canada. The term “Incomplete Vehicle Types” in these statements refers to the three types of the vehicles illustrated on this manual’s cover and listed in the chart on page 8.

The number preceding each Statement of Conformity refers to the number designation for a Part or a Section of Part 571 of the Federal Motor Vehicle Safety Standard.

The statements provided for each safety standard number are appropriate compliance representations for each Canadian safety standard number if this incomplete vehicle, identied by the VIN on the front of the document, was manufactured by Ford Motor Company for sale or use in Canada, except as may be noted at the conclusion of each safety standard number.

PART

565.4 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Part 565.4, Vehicle Identication Number, if the vehicle identication number mounted on the top of the instrument panel is not removed, altered, or modied and no actions are taken by the subsequent stage manufacturer that would obstruct the readability of the Vehicle Identification Number mounted on the top of the instrument panel.

565.4 The statements below are applicable to the following incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Part

565.4, Vehicle Identication Number, if:

• The E-Series vehicle identication number printed on the label afxed to the cover of this manual is mounted and displayed in accordance with the requirements of this Standard.

101 The statements below are applicable to the following

incomplete vehicle types when equipped with a driver seat:

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 101, Controls and Displays if:

• The controls, displays, and their identifications supplied by Ford Motor Company are not removed, relocated, altered, or modied.

• The components, wiring, and power supply installed by Ford Motor Company to illuminate any control, display, or their identification are not removed or altered so as to affect lighting performance.

• Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identications.

• The driver-seat is not replaced, relocated, or modied other than for the addition of seat trim.

Any controls, displays, and illumination added to this vehicle must conform to the requirements of this Standard.

101 The statements below are applicable to the following

incomplete vehicle types with no driver-seat:

• Incomplete E-Series Van

• Cutaway

This vehicle, when completed will conform to Standard 101, Controls and Displays if:

• The Seating Reference Point (see denition on page

5) and the seat back torso angle of the driver-seat when completed or installed by a subsequent stage manufacturer are located as shown in the Figure C page 32, for E-Series type vehicles.

• The c on tr ol s, displays, and their identifications supplied by Ford Motor Company are not removed, altered, or relocated.

• The components, wiring, or power supply installed by Ford Motor Company to illuminate any control, display, or their identication are not removed or altered so as to affect lighting performance.

• Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identications.

Any controls, d is pl ays, an d illumination added to this vehicle must conform to the requirements of this Standard.

101 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 101, Controls and Displays, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

E-SERIES (May, 2004) 9

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 11

102 The statements below are applicable to all incomplete

100

BRAKE

SERVIC

I N

INSTRUMENT CLUSTER

CABLE

STEERING COLUMN

CABLE

THUMB WHEEL

COLUMN SHIF

LEVER

FRONT OF VEHICLE

CABLE RETENTION BRACKET

SHIFT LEVER RETAINER PI

N800705 SCRE

TORQUE 20-29 IN.LB

[ ] ALL DIMENSIONS ARE INCHES

3.0-3.5 LB. WEIGHT

HAND TOOL

[2.375] ± 0.25 DIA.

(PRNDL)

HOLE: [1.125] DIA.

X [2.188] 0.25 DEEP

(PRNDL) ADJUSTMENT TOLERANCE

RIGHT LIMITLEFT LIMIT TARGET

vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 102, Transmission Shift Leve r Sequence, Starter Inte rlock, and Transm ission Braki ng Effect, if no alterations or adjustments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brakeshift interlock system, starter interlock system, wiring circuit from the interlock switch to the power source, and transmission gear selector indicator (PRNDL).

If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard.

INSTALLATION OF GEAR SELECTOR INDICATOR (PRNDL) FOR E-SERIES BASIC (STRIPPED) CHASSIS

102 The statements below are applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Standard 102, Transmission Shift Leve r Sequence, Starter Interlock, and Transmission Braking Effect if:

• No alterations or ad ju stments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brake-shift interlock system, the starter interlock system, and wiring circuit from the interlock switch to the power source.

• The E-Series Basic (Stripped) Chassis is equipped with a temporary transmission gear selector indicator (PRNDL) which must be replaced with the cluster and transmission gear selector indicator (PRNDL) that is shipped with the vehicle in the dunnage box and must be installed and adjusted following the instructions and specications shown in the gure below.

If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard.

1. Route the cable after the instrument cluster is installed in the vehicle. Do not kink the cable. Do not bend the cable to a radius less than 4.5 inches. Route the cable from the cluster in a counter-clockwise direction, under the steering column, using the screw provided. Do not wrap the cable around the steering column. The steering column shroud installation should not affect the cable routing or function.

2. Pull on the cable end loop for a functional check. The cable should operate with a similar effort as required prior to routing. Then place the cable loop on the shift lever retainer pin.

3. Rotate the column shift lever clockwise until it bottoms out in rst gear.

4. Rotate the column shift lever counter-clockwise 3 detents for Overdrive “Oval D” position for TorqShift™ transmissions.

5. Install a 3 pound weight, as dened in this illustration, on the end of the column shift lever.

6. Center the pointer in the middle of the “Oval D” position by rotating the thumb wheel.

7. Remove the 3 pound weight. The pointer must be within the tolerances as dened in this illustration.

8. After the steering column shrouds are installed, the transmission gear selector indicator (PRNDL) system must be checked for proper operation.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)10

103 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 103, Windshield Defrosting and Defogging Systems, if no alterations or adjustments are made to heater and blower assemblies, ducting, operating controls, electrical circuit from the blower assembly to the power source, windshield, coolant hoses from the radiator or engine to the heater, and if no obstructions are added that restrict or otherwise redirect the air flow from the defroster outlets to the windshield.

103 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 103, Windshield Defrosting and Defogging Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

104 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

This vehicle when completed, will conform to Standard 104, Windshield Wiping and Washing Systems, if no alterations are made to the windshield, the windshield wiping and washing system, including the electrical circuit from the windshield wiping and washing motors to the power source, and if no obstructions are added that restrict or otherwise redirect uid ow from the washer nozzles to the windshield.

104 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 104. Windshield Wiping and Washing Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

105 INFORMATION

Incomplete vehicle weight and dimensional information required for center of gravity calculations are available in the Ford Source Book. See your local Ford Dealer and refer to appropriate model year and specic vehicle for required information.

Abbreviation denitions and a vehicle diagram to assist with the equations for the Standard 105 segment are shown on page 14.

NOTE: 105 is an example of a standard with conformity statements that contain minimum requirements for completed vehicle Unloaded Vehicle Weight (UVW, see definition on page 5). Maximum UVW requirements are also found in various sections of this manual (see especially Standards 212/219 and 301 and related table, Table A). Completed vehicles must meet UVW limits imposed by all applicable requirements.

105 The statements below are applicable to the E-Series

cutaway when equipped with the School Bus Prep package and completed as a school bus:

This vehicle when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system reservoir labeling – Suspension ride height or spring rate – Hydro-Boost system – Power Steering pump and lines if used with

Hydro-boost – Engine belt drive system – Wheelbase

• The E-350 SRW Unloaded Vehicle Weight (see denition on page 5) is not less than the minimum value of 2540 kg [5600 lb].

• The E-350/450 DRW minimum UVW must be at least the weights shown on the following table:

MINIMUM UNLOADED VEHICLE WEIGHT (UVW)

Vehicle Weight Kilogram [Pound]

E-350 DRW 3673 [8100] E-450 DRW 4128 [9100]

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded.

• The transverse center of gravity is less than 50.8 mm [2.0 in] either side of the vehicle centerline for E-350 only.

• Service or parking brake pedal assembly operation must not be restricted by any alteration or added components.

• The horizontal and vertical center of gravity, of the completed vehicle at Unloaded Vehicle Weight, is within the minimum and maximum locations as dened in the following table:

CENTER OF GRAVITY FOR E-SERIES CUTAWAY

COMPLETED AS A SCHOOL BUS

E-350 E-350 E-450

Location SRW DRW DRW mm [in] mm [in] mm [in]

Vertical Maximum (1) 302.0 [11.9]

Horizontal Maximum (2) 2159.0 2718.0 [85.0] [107.0]

Horizontal Minimum (2) 1651.0 [65.0]

E-SERIES (May, 2004) 11

(1) Measured from top of frame at a point midway between

the centerlines of the front and rear axles.

(2) Measured rearward from the centerline of the front axle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 13

105 The statements below are applicable to the following

incomplete vehicle types if the GVWR is between 3500 kg [7716 lb] and 3629 kg [8000 lb]:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + 400 lb passenger load.

• The ser v ice or pa rking bra ke pedal assembly operation is not restricted by any alteration or added components.

• The horizontal center of gravity of the Second Unit Body (SUB) is rearward of L vehicle description in the chart below. Lmin does not apply to a SUB of 120 lb or less when installed rearward of the front seats and forward of the centerline of the rear axle. (Do not restrict the E-Series seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 32).

• The horizontal center of gravity for the SUB is:

† for the appropriate

min

– At or forward of the r ear axle center line. The

vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load CGv (Equation A) must not exceed 36.0 inches, when measured from the ground.

– Behind the rear axle centerline. The vertical center

of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load must fall within the appropriate range determined from Table E, page 16. The value of CGh (Equation B), which approximates the horizontal center of gravity of the completed vehicle, is used in Table E, to determine the vertical center of gravity limits for the completed vehicle. The value CGv (Equation A), which approximates the vertical center of gravity of the completed vehicle, must fall within the appropriate range determined from Table E.

EQUATION A

CGvbWb + CGvc Wc + 25P

CGv =

EQUATION B

Wrb + Wrc +

105 (Continued Next Page)

(

P x CG

(

)

x WB

HORIZONTAL CENTER OF GRAVITY

FORWARD LIMIT

Wheelbase L Vehicle Millimeter [inch] Millimeter [inch]

E-250 3505 [138] 1524 [60]

min

† L

= the minimum horizontal center of gravity of the

min

SUB measured in inches rearward from the centerline of the front axle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)12

105 (Continued)

105 The statements below are applicable to the following

incomplete vehicle types except when completed as a school bus, and if the GVWR is between 3629 kg [8000 lb] and 6373 kg [14,050 lb] inclusive:

• Incomplete E-Series Van or Wagon

• E-Series Cutaway

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system reservoir labeling – Suspension ride height or spring rate – Hydro-boost system – Power steering pump and lines if used with Hydro-

boost – Engine belt drive system – Wheelbase

• No additional sound deadene r or r ust proofing material, that may be applied to the vehicle, can interfere with proper parking brake cable function.

• No par t of add on equipment, i.e. toolboxes, flat bed attaching brackets, etc., can interfere with the movement of parking brake cables or air ow to rear brake assembly.

• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.

• E-Series Cutaway and Basic (Stripped) Chassis vehicles conform to the minimum SUB weights found in Table B, page 15.

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + Passenger Load (P). (See E-Series Passenger Load chart on this page.)

• The ser v ice or pa rking bra ke pedal assembly operation is not restricted by any alteration or added components.

• The SUB horizontal center of gravity must be at or forward of the rear axle centerline for the following vehicles:

- E-350/450 Basic (Stripped) Chassis

- E-350 Super Duty Cutaway (DRW)

- E-450 Super Duty Cutaway

The horizontal center of gravity for the SUB is:

– At or forward of the rear axle centerline. The vertical

center of gravity for the completed vehicle at GVWR CGv (Equation C) must not exceed 48.0 inches when measured from the ground.

– Behind the rear axle centerline. The vertical center

of gravity for the completed vehicle at GVWR must fall within the appropriate range determined from Table E page 16. The value of CGh (Equation D), which approximates the horizontal center of gravity of the completed vehicle, is used in Table E to determine the vertical center of gravity limits for the completed vehicle. The value of CGv (Equation C) which approximates the vertical center of gravity of the completed vehicle must fall within the appropriate range determined from Table E.

EQUATION C

CGvbWb + CG

CGv =

Wc + W

(

GVWR

)

+ 25P

EQUATION D

CGh =

Wrb + Wrc +

(

P x CG

(

)

+ W

)

x WB

GVWR

E-SERIES PASSENGER LOAD

GVWR [lb] P [lb] 0 - 7716 397

7717 - 10,000 400 10,001 - 19,000 500

E-SERIES (May, 2004) 13

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 15

FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES

CG OF SUB

CG OF COMPLETED VEHICLE

CG OF CHASSIS

GVWR

SUB

L† = Horizontal distance in inches between the SUB

center of gravity and the of the front axle.

P = Passenger load (See E-Series Passenger Load

Table page 13).

CGv = Vertical distance from the ground to the center of

gravity [inches] of the completed vehicle.

CGh = Horizontal distance from of the front wheels to

completed vehicle center of gravity [inches].

CGvb = Vertical distance from the ground to the center of

gravity of the SUB and/or permanently attached added equipment [inches].

CGvc = Vertical distance from the ground to the center

of gravity of the chassis [inches] (including cab if original equipment). (Taken from Table F, page 16).

CGhp = Horizontal distance from the of the front

wheels to the P [inches] (passenger load) (taken from Table D, page 16).

Wb = Weight of the SUB and/or permanently attached

added equipment [pounds].

Wrb = Weight at t he rear whe els o f the S UB

and/or permanently attached added equipment [pounds].

Wrc = Weight at the rear wheels of the vehicle (chassis

and cab) (fuel tanks full) [pounds]. Including option weight.

† Required for <8000 lb. GVWR calculations only. ‡ Required for ≥8000 lb. GVWR calculations only.

Wc = Weight of the vehicle (chassis and cab) (fuel

tanks full) [pounds]. Including option weight.

WB = Vehicle wheelbase [inches].

Wt = Total unladen weight = (Wb + Wc + P)

GVWR = Gross Vehicle Weight Rating of the vehicle

[pounds].

WI‡ = Remaining cargo capacity [pounds].

Where: Wl = GVWR - (Wb + Wc + P)

Wrl‡ = Weight of the remaining cargo capacity on the

rear wheels [pounds].

CGhI‡ = Horizontal distance from the

WrI =

(CGhI)W

of the front wheels to the cargo center of gravity [inches] (taken from Table C page 16). For many common vehicles, the CGhI is not given in the table, then it may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area.

SUB = A Second Unit Bo dy consis ts of the bod y

structure and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)14

TABLE A

Maximum Unloaded Vehicle Weight (UVW) for Incomplete Vehicles When Completed (2)

(This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR)

Wheelbase

Millimeter Maximum Model [inch] Unloaded Vehicle Weights – Kilogram [pound]

E-150 Regular Van 3505 [138] 2699 [5950](1) E-150 Regular Wagon 3505 [138] 2699 [5950](1) E-250 Regular and Extended Van 3505 [138] 3130 [6900] E-350 Regular and Extended Van 3505 [138] 3583 [7900] E-350 Regular and Extended Wagon 3505 [138] 3583 [7900] E-350 Cutaway 3505 [138] 3856 [8500] E-350 Basic (Stripped) Chassis SRW 3505 [138] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 3505 [138] 3946 [8700] E-350 Basic (Stripped) Chassis SRW 4013 [158] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 4013 [158] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 4470 [176] 3946 [8700]

(1) 2767 kg [6100 lb] When completed with 6 or less designated seating positions.

(2) Maximum unloaded vehicle weight values shown in this table are limits for purposes of F/CMVSS conformity only. See Emission

Certication information on page 49 for possible additional weight restrictions to meet emission requirements.

TABLE B

MINIMUM SUB WEIGHT

Minimum unloaded vehicle weight for cutaways completed as school buses is dened in Standard 105 requirements on page 11.

Kilogram Model [Pound]

E-350 Cutaway DRW 204 3505mm [138 in] WB [450]

E-350 Cutaway DRW 238 4013mm [158 in] WB [525]

E-350 Cutaway DRW 238 4470mm [176 in] WB [525]

E-450 Cutaway DRW 238 4013mm [158 in] WB [525]

E-450 Cutaway DRW 238 4470mm [176 in] WB [525]

E-350 Basic (Stripped) Chassis DRW 862 All WB [1900]

E-450 Basic (Stripped) Chassis DRW 998 All WB [2200]

E-SERIES (May, 2004) 15

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 17

TABLE C

CGhl = Horizontal distance from front axle to cargo CG:

Model WB (in) CGhl (in)†

Regular Van 138 116

†Extended Van or Extended Wagon 138 126 †Cutaway (SRW) 138 121

(DRW) 138 127

†Comm. Cab/Box Partition (DRW) 158 134 †RV (DRW) 158 138 †Comm. No Partition (DRW) 158 143

†RV (DRW) 176 153 †Comm. (DRW) 176 160

† If CGhI is not given in the table or if the location of your cargo is

not in the normal cargo area, then your CGhI may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area.

TABLE D

CGhp = Horizontal distance from front wheel to front

passenger load. (Dimensions are inches)

All E-Series† 48.5

† Except the E-Series Basic (Stripped) Chassis where the distance

from the of the front axle to the H point of the driver must be measured.

TABLE F

CGVC = Vertical distance from ground to chassis CG

(Dimensions are inches)

E-150 & E-250 Van <8000 lb GVWR = 28.5 E-250/350 SRW Van or Wagon >8000 lb GVWR = 32.0 E-350 Cutaway = 28.0 E-450 Cutaway = 26.5 E-350/450 Basic (Stripped) Chassis = 26.5

TABLE E

CGv = Vertical distance from the ground to the completed vehicle center of gravity [inch].

GVWR <8000 lb Use Equations A & B, page 12

Place the CGh of the vehicle (from Equation B) into the appropriate equations below to determine the allowable range of the CGv. If the actual CGv (from Equation A) is within the range calculated, the center of gravity location is acceptable.

Equation for CGv Range Model WB Upper Limit Lower Limit

E-150 138 CGv = 1.39 x CGh - 46.9 1.39 x CGh - 58.7 E-250 138 CGv = 1.39 x CGh - 47.1 1.39 x CGh - 59.0

GVWR > 8000 lb to <19000 lb Use Equations C & D, page 13

Place the CGh of the vehicle (from Equation D) into the appropriate equations below to determine the allowable range of the CGv. If the actual CGv (from Equation C) is within the range calculated, the center of gravity location is acceptable.

Equation for CGv Range

Model WB Upper Limit Lower Limit

E-250 138 CGv = 1.27 x CGh - 59.0 1.27 x CGh - 77.5 E-350 (SRW) 138 CGv = 1.27 x CGh - 60.0 1.27 x CGh - 80.0

<9600 Ib GVWR 158 CGv = 1.27 x CGh - 69.5 1.27 x CGh - 90.7

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)16

106 The statement below is applicable to all incomplete

TO INSTALL “CHMSL” UNWRAP TAPE FROM HARNESS IN THIS AREA AND REMOVE JUMPER CONNECTION TO EXPOSE THE “CHMSL CONNECTOR”.

E-SERIES CUTAWAY

FRONT OF

VEHICLE

THE “CHMSL” ELECTRICAL CONNECTION FOR AN ECONOLINE BASIC (STRIPPED) CHASSIS IS PROVIDED IN A DETAILED SCHEMATIC WHICH IS PACKAGED WITH THE BODY BUILDER ELECTRICAL CONNECTORS.

vehicle types:

This vehicle, when completed, will conform to Standard 106, Brake Hoses, if the brake hose assemblies supplied by Ford Motor Company are not removed, relocated, altered, or modied and if no brake hose assemblies are added.

108 In addition to the statements pertaining to particular

incomplete vehicle types which follow on pages 18 and 19, the statements immediately below, concerning Standard 108 Lamps, Reective Devices, and Associated Equipment are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:

No additio nal c omponent s may be added to the vehicle which require the use of tools to remove such components, for access to the headlamp aiming devices as provided by Ford Motor Company.

Daytime Running Lamps (DRL’s); Light Trucks for sale or use in Canada are equipped with DRL’s that meet the Canadian DRL requirements. As manufactured for Canada, the E-Series vehicles will meet the FMVSS 108 requirement for DRL’s when DRL’s are provided.

Co nformi ty with St and ard 10 8, S.1 2, Headlam p Concealment Devices, are not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

108 The statement below is applicable to the following

vehicle type with a GVWR of 4536 kg [10,000 lb] or less and a vehicle width less than 2032 mm [80.00 in]:

• Cutaway

This vehicle, when completed, will conform to Standard 108, L amps, Reflective Devices, and A ssociated Equipm ent if a Cent er High Mount ed S top Lamp (CHMSL) is installed so it meets all the requirements of this standard and is connected to the electrical power source as provided by Ford Motor Company. See the gure below for circuit location.

E-SERIES (May, 2004) 17

CENTER HIGH-MOUNTED STOP LAMP (CHMSL) ELECTRICAL CONNECTOR LOCATION

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 19

TABLE G

Standard 108 Lighting Equipment

E-Series Completed as Truck, MPV, Bus or School Bus

Width less than

2032 mm [80 in]

Item

Width 2032 mm

Headlamps S S Tail Lamps R/D R/D Stop Lamps R/D R/D Center High Mounted

Stop Lamp (CHMSL) R N License Plate Lamps R/D R/D Reex Reectors – Side Front S S

– Side Rear R R – Rear R R

Side Marker Lamps – Front S S – Rear R R

Back-Up Lamps R/D R/D Turn Signal Lamps – Front S S

– Rear R/D R/D Turn Signal Operating Unit S S Turn Signal Flasher (2) S S Vehicular Hazard Warning Signal

Operating Unit S S Vehicular Hazard Warning Signal

Flasher S S Identication Lamps – Front N R

– Rear N R Clearance Lamps – Front N R(1)

– Rear N R Parking Lamps R N School Bus Lamps and Switches R R

(School Bus except Multifunction School Activity Bus)

S Req ui re d on completed ve hi cl e and supplied with the

incomplete vehicle.

R Required on completed vehicle and not supplied with the

incomplete vehicle.

N Not required for completed vehicle.

D Required on completed vehicle and available as an option

(either on vehicle or shipped in dunnage).

(1) If a second unit body width is greater than 2032 mm [80 in] or

higher than the cutaway body, additional clearance lamps may be required that comply with this standard.

(2) Designed for two turn signal lamps per vehicle side (one front

and rear). If additional lamps are required, replace the turn signal asher with one having the correct lamp load rating.

108 The statements below are applicable to the following

[80 in] or more

108 The statements below are applicable to the following

incomplete vehicle type:

• Cutaway

This vehicle, when completed, will conform to Standard 108, L amps, Reflective Devices, and A ssociated Equipment, if all the required lighting equipment as indicated in Table G on this page (identied by the codes D, R and S) is designed and installed in accordance with the requirements of Standard 108 and the directions contained in this statement. Additionally, if the completed vehicle overall length is 9.14 meters [30 feet] or more, intermediate side marker lamps and reex reectors (not supplied by Ford Motor Company) are also required for compliance with Standard 108.

The items of equipment which are supplied by Ford Motor Company (identied by the code S in Table G, on this page) are designed and installed to conform to all the requirements of Standard 108. The completed vehicle will conform with these components if the subsequent stage manufacturer does not remove, relocate, alter, or modify such equipment or modify the power supply or wiring to such equipment, and does not complete the body in such a conguration as to impair the visibility and conformity to the photometric requirements of the installed lamps and reflective devices.

Specific requ irements for lighting and associated equipment are listed by incomplete vehicle type in Table G on this page.

Lamps, reective devices, and associated equipment necessary to complete the vehicle from an incomplete vehicle must conform to the equipment, locations, special wiring, visibility, photometric, and performance requirements of Standard 108 and to the applicable SAE standards or recommended practices referenced or sub-referenced in this Standard.

Al l elect rical equipment adde d to the vehic le by subsequent stage manufacturers must conform to the wiring practices set forth in the Electrical Wiring Section of the Ford Truck Body Builders Layout Book.

incomplete vehicle types:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 108, L amps, Reflective Devices, and A ssociated Equipment, if the subsequent stage manufacturer does not:

• Remove, al ter, replace, or relocate the lighting equipment installed on the incomplete vehicle

• Modify the power supply or wiring to such equipment

• Add any additional external lighting equipment

• Increase the overall width of the vehicle beyond that of the incomplete vehicle

• Complete, modify, or add components to the vehicle in such a manner as to impair the visibility and conformity to the photometric requirements of the installed lamps and reective devices

STATEMENTS OF CONFORMITY

108 (Continued Next Page)

E-SERIES (May, 2004)18

108 (Continued)

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108 The statements below are applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis:

Conformit y with Standard 108, Lamps, Reflective Devices, and Associated Equipment, is not substantially affected by the design of this incomplete vehic le; accordingly, Ford Mo tor Company makes no representation as to conformity with this standard. However, Ford Motor Company does represent that the items of lighting equipment, when provided in the E-Series dunnage box attached to the chassis, are designed to conform to the requirements of Standard 108.

108 Canadian Requirements:

Th e pre cedin g sta temen ts for Sta ndard 108 are appropriate compliance representations for CMVSS 108, Lighting, and CMVSS 108.1, Headlamps, if this vehicle is manufactured for sale or use in Canada, provided:

• No component of the Daytime Running Lamp (DRL) system is removed, relocated, or modied.

110 U.S. Requirements:

The statement below is applicable to all incomplete

vehicles with a GVWR of 4536 kg [10,000 lbs] or less:

This incomplete vehicle does not comply to FMVSS

110. In order to comply, the nal stage manufacturer must afx a tire placard as specied in paragraph S4.3 of FMVSS 110. The decal must be afxed to the B-Pillar. See below for placard content and note color and format requirements in S4.3.

111 The statements below are applicable to the following

incomplete vehicle types when equipped with a driver seat (including untrimmed seat) and a convex mirror on the passenger-side:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:

• The mirrors and their mounts as supplied by Ford Motor Company are not removed, relocated, replaced, or altered, except as noted below.

• No structural modifications are made to the body which would affect the stability of the mirror mounts.

• Any modications or additions made to this incomplete vehicle do not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle.

• The driver-seat is not replaced, relocated, or modied other than for the addition of seat trim.

If any alteration blocks the rear eld of view through the inside mirror, Standard 111 may require that the vehicle

E-SERIES (May, 2004) 19

have a at glass mirror on the passenger side.

111 The statements below are applicable to the incomplete

E-Series Van with no driver-seat when equipped with a convex mirror on the passenger-side:

This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:

• The mirrors and their mounts as supplied by Ford Motor Company, are not removed, relocated, replaced, or altered.

• No structural modifications are made to the body which would affect the stability of the mirror mounts.

• The Seating Reference Point (see definition on page 5) and the seat back torso angle of the driverseat installed or completed by the subsequent stage manufacturer are located as shown in Figure C page 32 corresponding to the particular incomplete vehicle type.

• Any modications or additions made to this incomplete vehicle do not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle.

If any alteration blocks the rear eld of view through the inside mirror, Standard 111 may require that the vehicle have a at glass on the passenger side.

111 The statement below is applicable to the following

incomplete vehicle types when not equipped with outside mirrors:

• Cutaway

• E-Series Basic (Stripped) Chassis

• Incomplete E-Series Van

Conformity with Standard 111, Rearview Mirrors, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

111 The statements below are applicable to the Cutaway

when equipped with outside mirrors:

Conformity with the stability requirements of Standard 111, Rearview Mirrors, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with stability requirements of this Standard. However, except for the stability requirement, this vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:

• The outside mirrors and their mounts, as supplied by Ford Motor Company, are installed in accordance with the instructions that accompany them and they are not relocated, replaced, or altered.

• The Cutaway with the School Bus Prep Package is completed as a school bus and any outside mirrors (not provided by Ford Motor Company) are installed in conformity with the requirements of Standard 111 for school buses.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 21

111 The statements below are applicable to the following

incomplete vehicle type when equipped with a at glass mirror on the passenger-side:

• Incomplete E-Series Van

This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:

• The mirrors and their mounts as supplied by Ford Motor Company are not removed, relocated, replaced, or altered.

• No structural modifications are made to the body which would affect the stability of the mirror mounts.

• Any modications or additions made to the incomplete vehicle must not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle.

113 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 113, Hood Latch Systems, if the hood latch system as provided by Ford Motor Company is not removed or altered.

113 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 113, Hood Latch Systems, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.

114 The statements below are applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less:

This vehicle, when completed, will conform to Standard 114, Theft Protection, if the following components, to the extent provided by Ford Motor Company, are not removed, relocated, altered, or modied in any way:

• Steering column locking mechanism system

• Ignition key/transmis sion shift interlock lock ing system

• Ignition key-locking system

• Key warning buzzer system

If any of the above components are added to the vehicle they must conform to the requirements of this Standard.

114 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 114, Theft Protection. See walk-in van denition, on page 5.

115 Canadian Requirements:

Th e stat eme nts for Part 565 .4 are appr opr i ate compliance representations for CMVSS 115, Vehicle Identication Number, if this incomplete vehicle was manufactured for sale or use in Canada.

116 The statement below is applicable to all incomplete

vehicle types:

This vehicle, when completed, will conform to Standard 116, M otor Veh icle Brake Flui ds, so lo ng as any brake uid added or replaced conforms to the DOT 3 specications of the standard and contaminants are not introduced into the hydraulic brake system.

118 The statement below is applicable to all incomplete

vehicle types not equipped with power windows when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less:

Co nformi ty wit h S tan dar d 118, Power Op erated Window, Partition, and Roof Panel Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. If any power operated window, partition, or roof panel systems are installed by subsequent stage manufacturers, they must conform to the requirements of Standard 118.

118 The statement below is applicable to all incomplete

vehicle types equipped with power windows when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less:

This vehicle, when completed, will conform to Standard 118, Power Operated Window, Partition, and Roof Panel Systems, if the power operated windows, motors, wiring, and key and switch activation systems, where provided by Ford Motor Company, are not removed, relocated, altered, or modified in any way. If additional power operated window, partition, or roof panel systems are installed by subsequent stage manufacturers, they must conform to the requirements of Standard 118.

119 The statement below is applicable to all incomplete

vehicle types:

All tires supplied by Ford Motor Company are in full conformity with Standard 119, New Pneumatic Tires for Vehicles Other than Passenger Cars.

If additional tires are installed or the existing tires are replaced by subsequent stage manufacturers, they must conform to the requirements of Standard 119.

120 The statement below is applicable to all incomplete

vehicles except for the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to the tire and rim selection requirements of Standard 120, Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars, if the tire and rim assemblies and the Incomplete Vehicle Label that is afxed to the vehicle are not removed, altered, or replaced.

120 The statements below are applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to the tire and rim selection requirements of Standard 120, Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars, if:

• The tire and rim assemblies, are not removed, altered, or replaced.

• The nal stage manufacturer must, in accordance with the requirements of Standard 120 and Par t 567 of Title 49 Code of Federal Regulations, afx a label to the completed vehicle indicating tire size, rim size, cold ination pressure, and the gross axle weight ratings. This information is provided on the label that is afxed to the cover of this manual for E-Series vehicles.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)20

124 The statements below are applicable to all incomplete

vehicle types:

This vehicle, when completed, will conform to Standard 124, Accelerator Control Systems, if:

• No alterations are made to the accelerator pedal, mounting hardware, adjustable pedal mechanism, or other components of the accelerator control system as installed by Ford Motor Company.

• No eq ui pment is added nor existing equipment mo dified which would restr ict o peratio n of the accelerator control system.

• No alterations are made to the Pedal Position Sensor and all associated hardware and wiring. See the gure below for component identication.

135 The statements below are applicable to the following

incomplete vehicle types if the GVWR is 3500 kg [7,716 lb] or less:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 135, Light Vehicle Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + 400 lb passenger load.

• The ser v ice or pa rking bra ke pedal assembly operation is not restricted by any alteration or added components.

• The horizontal center of gravity of the Second Unit Body (SUB) is rearward of L vehicle description in the table below. Lmin does not

† for the appropriate

min

apply to a SUB of 120 lb or less when installed rearward of the front seats and forward of the centerline of the rear axle. (Do not restrict the E-Series seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 32).

ELECTRONIC ACCELERATOR CONTROL

131 The statement below is applicable to the Cutaway

when equipped with the School Bus Prep Package and completed as a school bus:

Conformity with Standard 131, School Bus Pedestrian Safety Devices, is not substantially affected by the design of this incomplete vehicle. Accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

HORIZONTAL CENTER OF GRAVITY

FORWARD LIMIT TABLE

Wheelbase Lmin Model Millimeter [inch] Millimeter [inch]

E-150 3505 [138] 1473 [58] E-250 3505 [138] 1524 [60]

† L

= the minimum horizontal center of gravity of the SUB

min

measured in inches rearward from the centerline of the front axle.

E-SERIES (May, 2004) 21

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 23

• The horizontal center of gravity for the SUB is: – At or forward of the r ear axle center line. The

vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 397 lb passenger load CGv (Equation A) must not exceed 36.0 inches, when measured from the ground.

– Behind the rear axle centerline. The vertical center

EQUATION A

CGvbWb + CGvc Wc + 25P

CGv =

EQUATION B

Wrb + Wrc +

(

P x CG

(

CGh =

201 The statements below are applicable to incomplete

vehicles with a GVWR of 4536 kg [10,000 lb] or less, but excluding the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 201, Occupant Protection in Interior Impact, (excluding U.S. Requirements Section S6 addressed separately) if the following components, as provided by Ford Motor Company, are not removed, relocated, altered, or modied in any way:

• Instrument panel

• Interior compartment doors

• Sun visors

• Arm rests

Seat backs of front seats installed by Ford Motor Co mpa ny are des ign ed to meet th e seat back requirements of Standard 201. The seat mounted armrest on an untrimmed front seat must be completed so as to meet the requirements of this Standard.

)

x WB

)

If any of the above mentioned components (including front seats) are added to the incomplete vehicle by a subsequent stage manufacturer, these components must conform to the requirements of Standard 201 where applicable. When front seats are installed on an Incomplete E-Series Van or Cutaway the installed seat must be located within the dimensional specications for the Seating Reference Point and the torso angle as specied in Figure C page 32.

Because conformity of a completed vehicle to the seat back requirements of this standard is dependent upon the location of a seat installed by a subsequent stage manufacturer to the rear of another seat, Ford Motor Company makes no representation as to compliance of a completed vehicle to the seat back requirements if such a seat is installed.

If a vehicle is equipped with a Passenger Side Air Bag Delete Option a RH passenger seat should never be installed. If such a seat is installed Ford Motor Company makes no representation as to the compliance of the completed vehicle to Standard 201.

201 The statement below is applicable to the following

incomplete vehicle type if the GVWR is 4536 kg [10,000 lb] or less:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 201, Occupant Protection in Interior Impact, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this standard.

201U U.S. Requirements (Section S6):

The statements below are applicable to incomplete

vehicles with a GVWR of 4536 kg [10,000 lbs] or less, excluding buses with a GVWR more than 3860 kg [8510 lbs] and the Basic (Stripped) Chassis completed as a walk-in van type truck (which are exempt from the requirement):

This vehicle when completed, will conform to Standard

201U, Occupant Protection in Interior Impact - Upper Interior head Impact Protection, if the following components

as provided by Ford Motor Company, are not removed, relocated, altered, modied or additions added to the:

• A, B, Rear, or other Pillar and Trim, and Assist Handles

• Seat Belt ‘D’-Rings/Adjusters and ‘D’-Ring Covers

• Front or Rear Header and Trim

• Side Rails and Trim

• Upper Roof and Trim

If any of the above components are added to the incomplete vehicle by a subsequent stage manufacturer, these components must conform to the requirements of Standard 201U where applicable.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)22

202 The statements below are applicable to the following

incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less:

• Incomplete E-Series Van or Wagon when equipped with front seats

• Cutaway when equipped with front seats

This vehicle when completed, will conform to Standard 202, Head Restraints, if:

• No alterations are made to the head restraints, the seat assemblies and their anchorages, the oor pan, or oor pan reinforcements.

• The added seat tr im, on vehicles equipped with untrimmed front seats, is installed so that the physical dimension requirements for the head restraint, in this Standard, are met.

Any front outboard passenger seat, added to a cutaway equipped with the School Bus Prep Package and when completed as a truck, MPV, or bus (not school bus), must conform with the requirements of this Standard.

202 The statement below is applicable to the following

incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less:

• Incomplete E-Series Van with no front seats

• Cutaway with no front seats

• E-Series Basic (Stripped) Chassis

Conformity with Standard 202, Head Restraints, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

203 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less:

This vehicle, when completed, will conform to Standard 203, Impact Protection for the Driver from the Steering Control System, if the steering control system is not removed, relocated, altered, or modied in any way and no components or attachments are added to the steering control system that can catch the driver’s clothing or jewelry during normal driving maneuvers.

203 The statement below is applicable to the following

incomplete vehicle type if the GVWR is 4536 kg [10,000 lb] or less:

• E-Series Basic (Stripped) Chassis

The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the impact requirements of Standard 203, Impact Protection for the Driver from the Steering Control System. See walk-in van denition, on page 5.

203 Canadian Requirements:

Th e preceding stat eme nts for FMVS S 203 are appropriate compliance representations for CMVSS 203, Driver Impact Protection, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, the Basic (Stripped) Chassis will comply if no components or attachments are added to the steering control system that can catch the driver’s clothing or jewelry during normal driving maneuvers.

204 INFORMATION

Refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Second Unit Body

Attachment information that may aid in designing second unit bodies and their attachments to be compatible with E-Series vehicles.

204 The statements below are applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:

This vehicle, when completed, will conform to Standard 204, Steering Control Rearward Displacement, if:

• No components are added which could inuence the rearward displacement of the steering column.

• The steering column, steering inter mediate and coupling shaft, steering wheel, steering gear, steering linkage, related structural components, and attaching hardware, as installed by Ford Motor Company, are not removed, relocated, altered, or modied in any way.

• No alteration or modications are made to the body chassis, drivetrain, or front suspension from the B-pillar forward.

204 The statement below is applicable to the following

incomplete vehicle type if the GVWR is 4536 kg [10,000 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:

• E-Series Basic (Stripped) Chassis

The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 204, Steering Control Rearward Displacement. See walk-in van denition, on page 5.

E-SERIES (May, 2004) 23

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 25

205 The statement below is applicable to all incomplete

vehicle types, except the Basic (Stripped) Chassis:

Th is vehicle, w hen com ple ted , wi ll conform to Standard 205, Glazing Materials, if no alterations to or replacements of the installed glazing materials are made and if additional glazing materials installed by a subsequent stage manufacturer conforms to the requirements of Standard 205.

205 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 205, Glazing Materials, is not substantially affected by the design of this incomplete vehicle: accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

206 The statements below are applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis, when completed as a Truck:

This vehicle, when completed, will conform to Standard 206, Door Locks and Door Retention Components, if no alterations or adjustments are made to the door, door pillar structure, door locks, door latches, striker plates, hinges, and attaching hardware as installed by Ford Motor Company.

Any door added to this vehicle by a subsequent stage manufacturer must be equipped with door locks and door retention components that conform with this Standard.

206 The statement below is applicable to the following

incomplete vehicle type, when completed as a Truck:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 206, Door Locks and Door Retention Components, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

207, 208, 209, and 210 INFORMATION

For additional information to assist in designing seats, seat belt systems, and seat belt anchorages that comply with Standard 207, 208, 209, and 210 applicable to Incomplete E-Series Van and Cutaway vehicles with no front seats provided by Ford Motor Company, refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Seat and Lap & Shoulder Belt System information that is in addition to the statements which follow.

207 The statements below are applicable to the following

incomplete vehicle types when equipped with trimmed front seats:

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 207, Seating Systems, if no alterations are made to the seat assemblies, their anchorages, the oor pan, or oor pan reinforcements. Any seating system added to this vehicle must conform to applicable requirements of this Standard. When the Cutaway is completed as a school bus, see Standard 222 also.

If the front seat attaching hardware is removed for any reason, it must be reinstalled to the specications in Figure B for E-Series on page 31.

The Incomplete E-Series Recreational Van or the Incomple te E -S eries Wag on m ay have additional anchorages for rear seats other than the front driver and passenger seats. These locations apply to specic hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems, and hardware, Ford Motor Company makes no representation as to conformity with this Standard.

207 (Continued Next Page)

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)24

207 (Continued)

207 The statements below are applicable to the following

incomplete vehicle types when e qu ip ped wi th untrimmed front seats:

• Incomplete E-Series Van

• Cutaway

This vehicle when completed, will conform to Standard 207, Seating Systems, if:

• No changes or modications are made to the front seat frames, latches, hardware, and padding.

• The weight of each completely trimmed front seat does not exceed the value in Table H on this page.

• No modications are made to the oor pan in the area of the front seat attachments.

• The front seat and seat belt anchorages are not relocated.

If the front seat attaching hardware is removed for any reason, it must be reinstalled to the specications in Figure B for E-Series on page 31.

Any seating systems added to this vehicle must conform to the applicable requirements of this Standard.

The Incomplete E-Series Recreational Van may have additional anchorages for rear seats other than the front driver and passenger seats. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems, and hardware, Ford Motor Company makes no representation as to conformity with this Standard.

207 The statements below are applicable to the following

incomplete vehicle types with no front seats:

• Incomplete E-Series Van

• Cutaway

• E-Series Basic (Stripped) Chassis

Conformity with Standard 207, Seating Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

The Cutaway, when equipped with seat delete option, will include both front seat pedestals, pretensioner restraint systems, seat tracks, and a temporary driver’s seat. The pretensioner restraint system is attached to the seat track. Therefore, the completed seat assembly must comply with the requirements of Standard 207 and 210.

The Incomplete E-Series Recreational Van may have additional seat anchorages. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems, and hardware, Ford Motor Company makes no representation as to conformity with this Standard.

TABLE H

E-SERIES COMPLETED UNTRIMMED SEAT WEIGHT

Maximum Weight (lb) Description Driver-Side Passenger-Side

E-Series Captain’s Chair – Manual Tracks 59.0 61.0 E-Series Captain’s Chair – Manual Tracks – Manual Lumbar 62.0 68.0 E-Series Captain’s Chair – Power Tracks – Manual Lumbar 68.0 N/A

E-SERIES (May, 2004) 25

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 27

208 NOTE

An RCM (crash sensor and restraints control module) is located under the driver's seat. Care must be used to avoid damage to the RCM and sensor wiring during removal or reinstallation of the driver's seat. Refer to Figure E on page 33.

208 The statements below are applicable to the incomplete

E-Series Wagon and Van when equipped with trimmed front seats option if the GVWR is 3856 kg [8,500 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:

This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:

• The Unloaded Vehicle Weight exceeds 2166 kg [4775 lb] for the E150 and 2268 kg [5000 lb] for the E250.

• No components are added which could inuence the rearward displacement of the steering column.

• The seat belt components installed by Ford Motor Company are not removed, relocated, or altered. If the seat belt components are temporarily removed for any reason, they must be reinstalled to the specications as shown in Figure A on page 30.

• Front s eat s th at h ave be en removed for f inal manufacture are reinstalled to the specications as shown in Figure B on page 31.

• The seat belt warning system, as originally installed, is not removed, replaced, modified, or altered in any way.

• Window or roof modifications do not exceed the dened cut out areas shown in the Figures G1, G2 and G3 on pages 34, 35, and 36.

• No compressible material is installed between front seat assembly and the oor pan.

• No additional components or modications are made to the areas dened at the Occupant Protection Zone shown in Figure D on page 32.

• The Air Bag Supplemental Restraint System as originally installed (see Figure E on page 33), is not removed, relocated, altered, or modied in any way.

• Th e Air B ag Sup plemental Res tra int Sys tem Information Labels that are afxed to the front sun visors are visible, and not altered, modified, or removed. If the Air Bag Supplemental Restraint System Information Labels are not affixed to the front visors but shipped in dunnage, the following is necessary to meet Standard 208:

– The information label must be permanently afxed

to each visor in an upright position readable from the driver’s or passenger’s seating position.

– If the label is not visible when the visor is stored

(up position), an Air Bag Alert Label shall be placed on the visible surface of the visor as specied in Section 4.5.1(c) of Standard 208.

• No alteration or mod ifications are made to the body, chassis (including front bumper), drivetrain, body mounts, or front suspension from the B-pillar forward.

• Any front overhead console installed on an Incomplete E-Series is congured as follows:

– Front header (full width) overhead consoles may

extend down no more than 2 inches as measured from the Ford installed headliner† and extend rearward no more than 6 inches as measured from the midpoint between the Ford installed sun visor inboard retaining clips (vehicle centerline).

– Center roof mounted consoles may extend down

no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).

– A ll overh ead co nso les ar e designed and

manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.

Any seat belt assemblies added to a vehicle must conform to the applicable requirements of this Standard.

208 The statements below are applicable to the incomplete

E-Series Van when equipped with untrimmed front seats option if the GVWR is 3856 kg [8,500 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:

This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:

• The Unloaded Vehicle Weight exceeds 2166 kg [4775 lb] for the E150 and 2268 kg [5000 lb] for the E250.

• No components are added which could inuence the rearward displacement of the steering column.

• Front s eat s th at h ave be en removed for f inal manufacture are reinstalled to the specifications for appropriate vehicle type as shown in Figure B on page 31.

• The seat belt warning system, as originally installed, is not removed, relocated, altered, or modified in any way.

• The completed front seats are within the Seating Reference Point specications in Figure C on page

32.

• Window or roof modifications do not exceed the dened cut out areas shown in the Figures G1, G2 and G3 on pages 34, 35, and 36.

• No compressible material is installed between front seat assembly and the oor pan.

• No additional components or modications are made to the areas dened as the Occupant Protection Zone shown in Figure D on page 32.

208 (Continued Next Page)

† The Headliner Plane is dened on Figure G3 page 36, for vehicles

without the Ford headliner.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)26

208 (Continued)

• The Air Bag Supplemental Restraint System as originally installed (see Figure E on page 33), is not removed, relocated, altered, or modied in any way.

• Th e Air B ag Sup plemental Res tra int Sys tem Information Labels that are afxed to the front sun visors are visible, and not altered, modified, or removed. If the Air Bag Supplemental Restraint System Information Labels are not afxed to the front visors but shipped in dunnage, the following is necessary to meet Standard 208:

– The information label must be permanently afxed

to each visor in an upright position readable from the driver’s or passenger’s seating position.

– If the label is not visible when the visor is stored

(up position), an Air Bag Alert Label shall be placed on the visible surface of the visor as specied in Section 4.5.1(c) of Standard 208.

• After the front seats and B-pillar trim are installed, the seat belt system components must comply with:

– Adjustment requirements specified by s7.1 as

these requirements apply to seat belt t, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and

– Latch mechanism requirements specied by s7.2

as these requirements apply to the accessibility of seat belt components, and

– Latch plate access, retraction, seat belt guides, and

hardware requirements specied by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.

• The seat hardware including the seat back frames are free of sharp edges to prevent damage to the seat belt webbing during an impact.

• Do not obstruct the E-Series seat belt path in the area of “Point A” (Figure C, page 32). All seat belt contactable surfaces must be free of burrs, parting lines, sharp edges, or any other impediment that could impair or damage the seat belt in load bearing situations.

• No alteration or mod ifications are made to the body chassis (including front bumper), drivetrain, body mounts, or front suspension from the B-pillar forward.

• Any front overhead console installed on an Incomplete E-Series is congured as follows:

– Front header (full width) overhead consoles may

– Center roof mounted consoles may extend down

no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).

– A ll overh ead c ons oles are de signed an d

manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.

An y s eat belt as sem bli es adde d to this veh icl e must conform to the applicable requirements of this Standard.

208 The statements below are applicable to the incomplete

E-Series Van with seat delete option, if the GVWR is 3856 kg [8,500 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:

A seat delete option includes (does not delete) front seat pedestals, front seat tracks, front seat belt and buckle assemblies mounted to the seat tracks, restraint system, and fasteners, and comes with a temporary transit seat. Because the permanent seats to be installed by a subsequent stage manufacturer are critical to the performance of the completed vehicle and to the dynamic test requirements of Standard 208, Occupant Crash Protection, conformity to this Standard is not substantially affected by the design of this incomplete vehicle.

Ford offers the following information and guidelines to assist subsequent stage manufacturers who choose to install front seat assemblies in Incomplete E-Series Van vehicles.

• The completed front seat assemblies include the following Ford Motor Company components: Seat pedestal , seat tracks, r es trai nt s ystem, and all fasteners provided, and the fasteners are torqued to the specications listed in Figure B on page 31.

• The completed front seat assemblies, when installed, will have the same location, construction, and spatial relationship to the seating system as provided by Ford Motor Company.

• The Unloaded Vehicle Weight exceeds 2166 kg [4775 lb] for the E150 and 2268 kg [5000 lb] for the E250.

• No components are added which could inuence the rearward displacement of the steering column.

• The complet ed front seats a re installed t o the specications as shown in Figure B on page 31.

• The seats, seating hardware, seat belt warning system, and all attaching hardware are installed in accordance with, and comply with, this Standard and Standard 207, Seating Systems.

• The completed front seats, when installed, are located within the dimensional specications for the Seating Reference Point and the torso angle is positioned as specied in Figure C on page 32.

• Window or roof modifications do not exceed the dened cut out areas shown in the Figures G1, G2 and G3 on pages 34, 35, and 36.

208 (Continued Next Page)

† The Headliner Plane is dened on Figure G3 page 36, for E-Series

vehicles without the Ford headliner.

E-SERIES (May, 2004) 27

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 29

208 (Continued)

• No compressible material is installed between front seat assembly and the oor pan.

• No additional components or modications are made to the areas dened as the Occupant Protection Zone shown in Figure D on page 32.

• The Air Bag Supplemental Restraint System as installed by Ford Motor Company is not removed, relocated, modied, or altered in any way as shown in Figure E on page 33.

• Th e Ai r Ba g Su ppl emental Res tra int Syst em Information Labels that are afxed to the front sun visors are visible and not altered, modied, or removed. If the Air Bag Supplemental Restraint System Information Labels are not afxed to the front visors but shipped in dunnage, the following is necessary to meet Standard 208:

– The information label must be permanently afxed

to each visor in an upright position readable from the driver’s or passenger’s seating position.

– If the label is not visible when the visor is stored

(up position), an Air Bag Alert Label shall be placed on the visible surface of the visor as specied in Section 4.5.1(c) of Standard 208.

• After the front seats and B-pillar trim are installed, the seat belt system components must comply with:

– The seat belt buckle pretensioner, air bags, and

electronic sensor module are bar coded with a unique serial number which is matched to the vehicle VIN. The completed vehicle must contain the same seat belt buckle pretensioner, air bags, and electronic sensor module that were installed by Ford Motor Company in the incomplete vehicle.

– Adjustment requirements specified by s7.1 as

these requirements apply to seat belt t, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and

– Latch mechanism requirements specied by s7.2

as these requirements apply to the accessibility of seat belt components, and

– Latch plate access, retraction, seat belt guides, and

hardware requirements specied by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.

• The seat hardware including the seat back frames are free of sharp edges to prevent damage to the seat belt webbing during an impact.

• No alteration or mod ifications are made to the body, chassis (including front bumper), drivetrain, body mounts, or front suspension from the B-pillar forward.

• Any front overhead console installed on an Incomplete E-Series is congured as follows:

– Front header (full width) overhead consoles may

– Center roof mounted consoles may extend down

no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).

• All overhead consoles are designed and manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.

An y s eat belt as sem bli es adde d to this veh icl e must conform to the applicable requirements of this Standard.

208 The statements below are applicable to the following

incomplete vehicle types when e qu ip ped wi th untrimmed front seats or seat delete option and either the GVWR is over 3856 kg [8500 lb], or the Unloaded Vehicle Weight, when completed, is over 2495 kg [5500 lb]:

• Incomplete E-Series Van

• Cutaway

This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:

• The seat belt components installed by Ford Motor Company are not removed, relocated, altered, or modied. If the seat belt components are temporarily removed for any reason, they are reinstalled to the specications for E-Series shown in Figure A on page 30 and Figure B on page 31.

• After the front seats and B-pillar trim are installed, the seat belt system components comply with:

– Adjustment requirements specified by s7.1 as

these requirements apply to seat belt t, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and

– Latch mechanism requirements specied by s7.2

as these requirements apply to the accessibility of seat belt components, and

– Latch plate access, retraction, seat belt guides, and

hardware requirements specied by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.

• No actions are taken which would impair the integrity of the seat belt systems and the seat belt warning system.

STATEMENTS OF CONFORMITY

208 (Continued Next Page)

† The Headliner Plane is dened on Figure G3 page 36, for E-Series

vehicles without the Ford headliner.

E-SERIES (May, 2004)28

• The Air Bag Supplemental Restraint System as installed by Ford Motor Company (see Figure E on page 33) is not removed, relocated, modied or altered in any way. Ford technical bulletin procedures for relocating the oor-mounted restraints delete resistor and bracket may be followed for vehicles that have an option that deletes the front passenger restraint system.

• Th e Air B ag Sup plemental Res tra int Sys tem Informatio n Labels that are affixed to the fron t sunvisors are visible and not altered, modied, or removed.

An y s eat belt as sem bli es adde d to this veh icl e must conform to the applicable requirements of this Standard.

208 The statement below is applicable to the following

incomplete vehicle types when equipped with Ford trimmed front seats and either the GVWR is over 3856 kg [8500 lb], or the Unloaded Vehicle Weight, when completed, is over 2495 kg [5500 lb]:

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:

• The seat belts, seat belt war ning syste m, and attaching hardware installed by Ford Motor Company are not removed, relocated, altered, or modied.

• No actions are taken which would impair the integrity of the belt and seat belt warning systems. (A seat belt warning system is not required for a vehicle with a GVWR over 4536 kg [10,000 lb] or for a bus).

• Any rear seats installed by Ford Motor Company that are temporarily removed for any reason are returned to their original location and condition in the vehicle.

• The Air Bag Supplemental Restraint System as installed by Ford Motor Company (see Figure E on page 33) is not removed, relocated, modified or altered in any way. Ford technical bulletin procedures for relocating the floor-mounted restraints delete resistor and bracket may be followed for vehicles that have an option that deletes the front passenger restraint system.

• Th e Air B ag Sup plemental Res tra int Sys tem Informatio n Labels that are affixed to the fron t sunvisors are visible and not altered, modied, or removed. If the Air Bag Supplemental Restraint System Information Labels are not affixed to the front visors but shipped in dunnage, the following is necessary to meet Standard 208:

– The information label must be permanently afxed

to each visor in an upright position readable from the driver’s or passenger’s seating position.

– If the label is not visible when the visor is stored

(up position), an Air Bag Alert Label shall be placed on the visible surface of the visor as specied in Section 4.5.1(c) of Standard 208.

An y s eat belt as sem bli es adde d to this veh icl e must conform to the applicable requirements of this Standard.

208 The statement below is applicable to the following

vehicle type:

• E-Series Basic (Stripped) Chassis

Co nformi ty wit h S tan dar d 208, O ccu pan t C rash Protection, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity of this vehicle. Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard.

208 Canadian Requirements:

The preceding statements and suppor ting figures for FMVSS 208, on pages 26-36, are appropr iate compliance representations for CMVSS 208, Occupant Restraint Systems in Frontal Impact, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 208 paragraphs (13), (14), and (15) are substituted for the reference to FMVSS 208 Section 7.1; CMVSS 208 paragraph (20) should be substituted for the reference to FMVSS 208 Section

7.2; and CMVSS 208 paragraphs (29), (30), (31), (32), (33), (34), (35), (36), (37), (38), (39), and (40) should be substituted for the reference to FMVSS 208 Section 7.4.

WARNING: VEHICLES EXCEPT STRIPPED CHASSIS, INCLUDING

THOSE OVER 3856 kg [8500 lb] GVWR AND/OR OVER 2495 kg [5500 lb] UVW ARE EQUIPPED WITH A FRONT ROW OCC UPANT SUPPLEMENTAL RESTRAI NT SY STE M (AIR BAG(S), WIRING, AND S ENS ORS IN CLU DING AN RC M UND ER DRIVER' S SEAT) AND PYROTECHNIC BUCKLE PRETENSIONER(S). DELETE OF FRONT PASSENGER ACCOMMODATIONS INCLUDING RESTRAINTS, SEAT, AND PEDESTAL CO UPL ED WI TH T HE AD DIT ION O F DEL ETE RESISTORS IN THE SENSOR SYSTEM CIRCUITRY IS AVAILABLE ON SOME VEHICLES. MODIFICATIONS TO THE VE HIC LE FORWARD OF O R NE AR T HE CRASH SENSORS SHOWN IN FIGURE E PAGE 33 MAY EFFECT THE DEPLOYMENT OF THE AIRBAG(S) AND PRETENSIONER(S).

E-SERIES (May, 2004) 29

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 31

CRITICAL CONTROL ITEM

VIEW

CRITICAL CONTROL ITEM

FRONT OF

VEHICLE

FRONT OF

VEHICLE

3C24-15602B82 ADJ. ASY.

PANEL ASY. UPPE

F65B-15602B90 COVER ASY.

3C24-1560262 COVER ASY. 1 REQ’D. EA. SIDE

N806773-S190 NUT TORQU

40.0

± 6.0 Nm

15611B0

BELT AN

RETRACTOR ASY.

ALL CUTAWAY

MODELS ONLY

368273-S100 BOLT TORQU

47.5 ± 7.2 Nm

PANEL ASY. COVE

ALL WAGON

– VAN MODELS ONLY DRIVER – SEAT (LEFT HAND) INSTALLATIO

SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT TO RETRACTOR INTO VEHICLE

CUTAWAY & VAN MODEL

3C24-15602B82 ADJ. ASY.

F65B-602B90 COVER ASY.

3C24-1560262 COVER ASY. 1 RE

Q’D. EA. SIDE

N806773-S190 NUT TORQU

15611B08

BELT AN

RETRACTOR ASY.

SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT TO RETRACTOR INTO

VEHICLE.

PANEL ASY. COVER

ALL WAGON

– VAN MODELS ONLY PASSENGER SEAT (RIGHT HAND) INSTALLATIO

ALL CUTAWAY

MODELS ONLY

[29.5 ± 4 ft-lb]

[35 ± 5 ft-lb]

40.0 ± 6.0 Nm

[29.5 ± 4 ft-lb]

BOLT TORQU

47.5

± 7.2 Nm

[35

5 ft-lb]

PIA

BOLT TORQU

47.5 ± 7.2 Nm [35 ± 5 ft-lb]

PIA

BOLT TORQUE

47.5 ± 7.2 Nm [35 ±

5 ft-lb]

PIA

BOLT TORQU

47.5

± 7.2 Nm

[35 ± 5 ft-lb]

VIEW IN CIRCLE

6.0 MIN. CLEARANCE

TO ALL ADJUSTED POSITIONS

6.0 MIN.

SEAT BELT WEBBIN

6.0 MIN. CLEARANCE

AROUND BELT PERIPHERY AT MAX. TRAVEL POSITIONS

6.0 MIN.

UP POSITION

6.0

RETRACTOR

9.5 RADIUS MIN.

13.0 MIN. FROM

COVER TO RELEASE KNOB

2.0 MIN.

(WITH DRING LOCATED ON

SHLDR.BOLT)

1560262 REF.

(3) FULL THREAD EXPOSED

DOWN ADJUSTED

POSITION

UP ADJUSTED

POSITION

6.5 MIN. FROM

RELEASE KNOB

TO INTERIOR TRIM

12.5 MIN.

OVERLAP

ALL DIMENSIONS ARE IN MILLIMETERS

NOTE

SECTION AA

SECTION BB

MAIN VIEW

SECTION DD

FRONT OF

VEHICLE

INTERIOR TR

[.37 IN]

[.50 IN

]

[.25 IN

]

[.50 IN]

[.08 IN]

[.24 IN]

[.24 IN

]

[.24 IN

]

[.24 IN]

[.12 IN

]

[ ] DIMENSIONS ft-lb OR INCHE

FIGURE A – E-SERIES FRONT SEAT RESTRAINT SYSTEM

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)30

POWER L.H. SHOWN

SEAT ASY.

N802351-S424 STUD 2 REQ’D.

2C24-1561701-A

POWER TRACK A

FRT. ST.

56912-S58 SCREW 4.2 x 19 TA

PPING

N800937-S424 NUT & WASHER ASY. 2 REQ’D. TO

RQUE 55.0 8.3 Nm

N620481-S58 NUT M8 x 1.75 HEX FLANGE TO

RQUE 25.0 3.8 Nm

W705944-S424 SCREW 2 REQ’D. TO

RQUE 55.0 8.3 Nm

611D02A STUD COVER 4 REQ’D.

XC25-1560094-B SUPPORT ASY.

SWITCH ASY. ST. CONTROL

F8UB-14A699-A

WIRING ASYSEAT

CONTROL FEED

N801078-S424 SCREW M8 x 1.25 HEX 4 REQ’D. TO

RQUE 25.0 3.8 Nm

PIA BOLT

RQUE

35.0 6.0 Nm

JUMPER

F8UB-14A699AA WIRING ASYSEAT CONTROL FEED

JUMPER

[29.5 4 ft-lb]

[18.4 + 2.8 ft-lb]

[40.6 + 6 ft-lb]

[18.4 + 2.8 ft-lb]

[40.6 6 ft-lb]

XL3T-14A701-A

PRESS

CLEARANCE

ZONE

CLEARANCE

ZONE

SIDE VIEW REAR VIEW

CENTER OF VEHICLE

FRONT OF VEHICLE

PRETENSIONER CLEARANCE ZONE

579988 SEAT

PASS XC2A-156202-A BUCKLE ASY.

DR. 571485 PASS. 571481

R.H. TRACK

FOR SHIPPING PURPOSES ONLY, ONLY 4 SCREWS (NO NUTS & BOLTS)

611D02A STUD COVER 4 REQ’D.

N800937-S424 NUT & WASHER ASY. 2 REQ’D.

55.0 8.3 Nm

571483 DR. 571479 PASS.

R.H. TRACK

N011488-S424 STUD 2 REQ’D.

XC25-1560094-A (MANUAL) SUPPORT ASY.

COVER FRT ST. PVT.

PIA BOLT

RQUE

40.0 6.0 Nm

W705944-S424 SCREW 2 REQ’D.

55.0 8.3 Nm

F7U-S14A699DB

WIRE ASY.

2C24-1561755-B (DR.) HDL.FRT.ST.TRK.

THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS. THE BUCKLE MOVES DOWNW

ARD THROUGH THE SHADED

ZONE AND MUST NOT CONTACT ANY COMPONENT WHICH

MAY DEGRADE ITS PERFORMANCE

IMPORT

ANT:

DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED

AREA, OR ALTER OR MODIFY THIS AREA.

VIEW A

[ ] DIMEN SIONS ft-lb OR INCH ES

[29.5 4 ft-lb]

[40.6 6 ft-lb]

DR. 3C34-1561203-A

O/B TRUCKS

MANUAL R.H. SHOWN

SEAT ASY.

N801078-S58 SCREW M8x1.25 HEX 4 REQ’D. TORQUE

25.0 3.8 Nm

4C24-15618B47-AA TRACK ASY.

XC2A-1561202-A PYROTECHNIC

ASY. R.H.

PIA BOLT TO

RQUE

35.0 5.0 Nm

COVERFRT. ST. PIVOT

56912-S58 SCREW 4.2 x 19.0 TA

PPING

1C2415466B00A

BRKT CHILD SEAT

N620432-S58 M10 HEX NUT HD. NUT W/WASHER 4 REQ’D.

N802351S424 STUD 2 REQ’D.

2C24-1562506-A

SUPPORT ASY.

(R.H. MNL)

F7US-14A699DB WIRE ASY.

2C241561755A

HANDLE FRT. ST. TRACK

IC24-15618B46-B

TRACK ASY.

[18.4 2.8 ft-lb]

[29.5 4 ft-lb]

611D02A STUD COVER

4 REQ’D.

[40.6 6 ft-lb]

TORQUE 55.0 8.3 Nm

N811326S424

SCREW 2 REQ’D.

E-SERIES DRIVER (L.H.) SEAT DELETE OPTION

FIGURE B – E-SERIES FRONT SEAT INSTALLATION

E-SERIES (May, 2004) 31

E-SERIES PASSENGER (R.H.) SEAT INSTALLATIONE-SERIES DRIVER (L.H.) SEAT INSTALLATION

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 33

SRP INFORMATION POINT A

IMPORTANT:

THE TORSO ANGLE IS DETERMINED BY

USING THE METHOD SPECIFIED IN

SAE J826 (MAY 1987)

POINT

[ ] DIMENSIONS ARE INCHES

POINT A

DRIVER SEAT

PASSENGER SEAT

VEHICLE

DRIVER SIDE ONLY

TORSO ANGLE

18 DRIVER 21 PASSENGE

SEAT BASE

L OUTSIDE FRONT

FASTENER

L OUTSIDE FRONT FASTENER

THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE AT DESIGN POSITION. ECONOLINE VAN VEHICLES AT DESIGN POSITION WILL BE LEVEL FRONT TO REAR, AND SIDE TO SIDE, ON THE UPPER SURFACE OF THE RIBBED FLOOR PANEL FROM THE B-PILLAR REARWARD.

L OUTSIDE FRONT FASTENER

SEAT BACK

PIVOT

[0.24]

510.

[20.08

]

HEEL

POINT

SRP HAS A 12.7 [0.50] RADIAL TOLERANCE PERMITTED FROM

BASE SRP

DO NOT INSTALL ADDITIONAL COMPONENTS IN THE

SHADED AREAS, OR ALTER OR MODIFY THESE AREAS.

(SEAT POSITION IS 10.0mm [0.39 IN] FORWARD (SEAT POSITION IS AT THE MIDPOINT OF REARMOST POSITION) OF AVAILABLE TRAVEL)

A B C D E F MIN. MAX.

DRIVER – SEAT (VAN AND CUTAWAY) 217.8 105.0 384.2 356.0 67.0 937.4 [8.57] [4.13] [15.13] [14.01] [2.64] [36.90]

PASSENGER – SEAT (VAN AND CUTAWAY) 277.3 103.0 377.0 412.0 65.0 960.1 [10.92] [4.06] [14.84] [16.22] [2.56] [37.80]

FIGURE C – E-SERIES SEATING REFERENCE POINT (SRP)

FIGURE D – E-SERIES OCCUPANT PROTECTION ZONE

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)32

FIGURE E1 – E-SERIES SUPPLEMENTAL RESTRAINT

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 

  

DO NOT RELOCATE. MUST BE METAL-TO-METAL CONTACT

RESTRAINT CONTROL MOD ULE UNDER DRI VER'S SEAT

FRONT OF

VEHICLE

14A200 WIR ASY WDO REG RLY SW

REF FRONT FLOOR PAN

N808248-S190 SCREW TORQUE 12.0 ± 1.8 Nm [9 ± 1.3 ft-lb]

14B321-A SNS & BRKT ASY - A/BAG FRT

FIGURE E2 – E-SERIES RESTRAINT CONTROL MODULE

SYSTEM (Air Bags, Sensors, and Wiring)

Sensor system also connected to pyrotechnic buckle pretensioners (not shown), which are assembled to the front seat pedestals. Passenger air bag and buckle pretensioner replaced by cover/delete resistor and bracket/delete resistor, respectively, on vehicles that have an option that deletes the front passenger restraint system.

FIGURE E3 – E-SERIES RESTRAINT CONTROL MODULE

E-SERIES (May, 2004) 33

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 35

CUT LI NE

SECTION BB

CUT LI NE

SECTION CC

SECTION DD

CUT LI NE

SECTION AA

FRONT OF

VEHIC LE

NOTE: SHADED AREA REPRE SENTS MAXIMUM OPENIN G IN B ODY

PANELS.

THE S ECTIONS SHOWN ARE A LARGER SCALE T HAN THE SIDE V IEW

FOR TH E PURPO SE OF CLARITY.

THE S POTWELD S (X) IN THIS

AREA MUS T REMAI N INTACT.

711.

[ 28. 00

]

MAXIM UM

[ ] DIMENSIONS ARE INCHES

711.

[ 28. 00

]

MAXIM UM

FIGURE G1 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (DRIVER SIDE – L.H.)

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)34

FRONT OF

VEHICLE

THE SPOTWELDS ( X ) IN THIS AREA MUST REMAIN INTACT.

NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIE

FOR THE PURPOSE OF CLARITY.

[ ] DIMENSIONS ARE IN I NCHES

CUTLIN

SECTION EE

SECTION FF

CUTLINE

SECTION GG

CUTLINE

533.4

[21.00

]

MAXIMUM WITH

SLIDING DOOR

711.

[28.00

]

MAXIMU

WITH CARG

DOORS

FIGURE G2 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (PASSENGER SIDE – R.H.)

E-SERIES (May, 2004) 35

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 37

END OF ROOF

EXTENDED VA

END OF ROOF

EXTEN DED VA

OR WAGO N

REGUL AR VA

NOTE: SHADED AREA REPR ESENTS MAXIMUM OPEN ING IN BODY

PANELS.

[ ] DIMENSIONS

ARE I NCHES

OUTER EDGE

TROUGH

REGULAR VAN

"B" PILLAR REINFORCEMENT

WINDSHIELD HEADER

FORWARD CUT LINE

50.8

[2.00]

SECTION AT C

OF ROOF

HEADLINER PLANE, FOR VEHICLES NOT EQUIPPED WITH A

FORD HEADLINER, USE A PLANE DETERMINED BY A

POINT AT THE LOWER REAR OF THE WINDSHIELD HEADER

TO THE MIDPOINT ON THE BPILLAR REINFORCEMENT.

203.2

[8.00]

203.

[8.00]

CUT

LINE

CUT

LINE

FRONT OF

VEHIC LE

END OF ROOF

CUTAWAY

FIGURE G3 – ROOF PANEL REMOVAL AREA – E-SERIES

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)36

209 The statements below are applicable to the following

incomplete vehicle types with front seat(s):

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 209, Seat Belt Assemblies, if:

• No alterations or replacements are made to the seat belt assemblies and attaching hardware.

• No action is taken that would impair the integrity of the seat belt system provided.

Any seat belt assemblies added to a vehicle must conform to the requirements of this Standard.

209 The statement below is applicable to the following

incomplete vehicle types with no front seats:

• Incomplete E-Series Van

• Cutaway

Conformity with the pelvic restraint, upper torso restraint, release, adjustment, and webbing requirements of Standard 209, Seat Belt Assemblies as specied in s4.1 (b), (c), (e), (g), and (h), respectively, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with these requirements of Standar d 209. However, Ford Moto r Company represents that the seat belt assemblies provided by Ford Motor Company conform to the applicable single occupancy hardware, attachment hardware, strap, marking, installation instructions, usage and maintenance instructions, workmanship, webbing performance, hardware performance, and assembly performance requirements detailed in the remaining paragrap hs of the s tandard n ot specif ied above, provided no alterations or replacements are made to the seat belt assemblies and attaching hardware, as provided by Ford Motor Company, an d further provided that no action is taken by subsequent stage manufacturers to impair the integrity of the seat belt system provided. Any additional seat belt assemblies installed must confor m to the requirements of this Standard.

209 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 209, Seat Belt Assemblies, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.

209 Canadian Requirements:

The preceding statements for FMVSS 209 are appropriate compliance representations for CMVSS 209, Seat Belt Assemblies, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 209 paragraphs (2) and (3), (4) and (5), (14), (15), and (7) are substituted for the reference to FMVSS 209 Sections

4.1(b), (c), (e), (g), and (h), respectively.

210 The statements below are applicable to all incomplete

vehicle types except Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 210, Seat Belt Assembly Anchorages, if:

• No alterati ons a re ma de to the fro nt se at be lt anchorages, front seat belt assemblies, oor pan, oor pan reinforcements, or body mounts.

• E-Series window or roof modications do not exceed the dened cut out areas shown in Figures G1, G2 and G3 on pages 34, 35, and 36.

The Incomplete E-Series Van and Cutaway with no front seats must have completed front seats installed that conforms to the seat location criteria shown in Figure C on page 32.

The Incomplete E-Series Van, Wagon, and Cutaway must have a seat belt anchorage system installed for each additional designated seating position that co nforms t o t he app lic able requir eme nts of th is Standard.

The Incomplete E-Series Recreational Van or the E- Ser i es Wag on may have additi ona l seat belt anchorages for designated seating positions other than the front driver and passenger seats. Also, Cutaway vehicles may have additional seat belt anchorages for designated seating positions on optional seats not provided on incomplete vehicles. These locations apply to specic hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems, and hardware, Ford Motor Company makes no representation as to conformity with this Standard.

The Incomplete E-Series Recreational Van, when equipped with the seat delete option, will include both front seat pedestals, pretensioner restraint systems, seat tracks, and a temporary driver’s seat. The pretensioner restraint system is attached to the seat track, therefore, the completed seat assembly must comply with the requirements of Standard 210 and 207.

210 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 210, Seat Belt Assembly Anchorages, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

210.1 Canadian Requirements applicable to all incomplete vehicle types with a GVWR of 3856 kg [8,500 lb] or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less except Basic Stripped Chassis:

210.1 (Continued on Next Page)

E-SERIES (May, 2004) 37

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 39

210.1 (Continued)

This vehicle, when completed, will conform to Standard

210.1, User-Ready Tether Anchorages for Restraint Systems, if:

• No alternations are made to the front passenger seat tether anchorages and access to the anchorages is not restricted; the front passenger seat, its anchorages, the oor pan and its reinforcements are not altered; and no seats are added.

Because the addition of seats would change compliance with this Standard, Ford Motor Company makes no representations as to conformity with this Standard for any vehicle that has seats added by Intermediate or Final Stage Manufacturers.

210.1 Canadian Requirements applicable to the following incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Co nformi ty wi th Standard 21 0.1 , Use r-Ready Tether A nchorages for Res traint Sy stems, is not substantially affected by the design of these incomplete vehicles; accordingly, Ford Motor Company makes no representations as to conformity with this Standard.

210.2 Canadian Requirements:

The statement below is applicable to all incomplete

vehicle types if the GVWR is 3856 kg [8,500 lb] or less, except Basic Stripped Chassis. It is also applicable to buses (including school buses) with a GVWR of 4536 kg [10,000 lb] or less:

This vehicle, when completed, will conform to Standard

210.2, Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions, if:

• No alterations are made to the front passenger seat and no seats are added.

210.2 Canadian Requirements:

The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conform ity with Standard 210. 2, Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representations as to conformity with this Standard.

212/ Note 219 The terms “body” or “body structure,” in the 212 and

219 statements that follow, include any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer as well as the basic body or body structure.

212/ INFORMATION 219 Refer to the Design Recommendations section in the

Ford Truck Body Builders Layout Book for Second Unit Body Attachment information to aid in designing second unit bodies and their attachments for compatibility with E-Series vehicles.

212/ The statements below are applicable to the following 219 incomplete vehicle types if the GVWR is 4536 kg

[10,000 lb] or less:

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 212 Windshield Mounting, and Standard 219, Windshield Zone Intrusion, if:

• The following windshield system components, related structural components, and hardware, as installed by Ford Motor Company, are not removed, relocated, altered, or modied in any way except as specied in this manual:

– Windshield and windshield mounting system – Cab and front end structural components including

the roof, pillars, cowl, cowl reinforcements, ho od, doo rs, fend ers, hood re stri cto rs and ap ron reinforce men ts, a nd frame and f rame

reinforcements – Radio antenna and air cleaner assembly – Doors and hood mounting, hinging, and latching

systems – Hood ornamentation – Bumper and bumper mounting system†

• No alteration or modication made to the incomplete vehicle as manufactured by Ford Motor Company and no compon ents or str ucture inst alled by a subsequent stage manufacturer results in any loss of windshield retention (as dened in Standard 212) or any penetration of the inner surface of the windshield or intrusion into the protected zone (as dened in Standard 219) when the vehicle is impacted in any manner specied by applicable provisions of Standard 212 or Standard 219. Sections S6.1(b) and S7.7(b) of Standards 212 and 219, respectively, state vehicles are tested to a maximum Unloaded Vehicle Weight of 2495 kg [5500 lb].

• The completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table A on page 15 corresponding to the vehicle's model and wheelbase.

STATEMENTS OF CONFORMITY

† Temporary removal of the front bumper and front bumper mounting

system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual should not adversely affect the compliance of a completed vehicle to Standards 212 and 219.

E-SERIES (May, 2004)38

212/ The statement below is applicable to the following 219 incomplete vehicle type if the GVWR is 4536 kg [10,000

lb] or less:

• E-Series Basic (Stripped) Chassis

The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 212, Windshield Mounting, and Standard 219, Windshield Zone Intrusion.

212/ Canadian Requirements: 219 The preceding statements for FMVSS 212/219 are

appropriate compliance representations for CMVSS 212, Windshield Mounting, and CMVSS 219 Windshield Zone Intrusion, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 212 and 219 paragraphs (5.1) and (8) are substituted for the reference to FMVSS 212 and 219 Sections 6.1(b) and 7.7(b) respectively.

213 The statement below is applicable to all incomplete

vehicle types:

Conformity with Standard 213, Child restraint systems, is not substantially affected by the design of the incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard. Any child restraint system that is added or incorporated into the design of a designated seating position must conform to the requirements of this standard.

214 The statements below are applicable to the following

vehicle types if the GVWR is 4536 kg [10,000 lb] or less:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 214, Side Impact Protection, if:

• No alterations, modications, or replacements are made to the door, surrounding door structure, door hinges, door latches and strikers, or any attaching hardware as provided by Ford Motor Company.

• The Incomplete E-Series Van or Wagon roof or window modications do not exceed the dened cut out areas shown in Figure G1, G2 and G3 on pages 34, 35, and 36, respectively.

214 The statements below are applicable to the E-Series

Cutaway if the GVWR is 4536 kg [10,000 lb] or less:

This vehicle, if equipped with both front doors as manufactured by Ford Motor Company when completed, will conform to Standard 214, Side Impact Protection, if no alterations, modifications, or replacements are made to the door, surrounding door str ucture, the entire roof structure, door hinges, door latches and strikers, or any attaching hardware provided by Ford Motor Company.

This vehicle if equipped with a driver-side door only when completed, will conform to Standard 214, Side Impact Protection, for that door only if no alterations, modications, or replacements are made to the door, surrounding door structure, the entire roof structure, door hinges and strikers, or any attaching hardware provided by Ford Motor Company.

Any side door and surrounding body structure added to this vehicle, if a designated seating position is less than 254 mm [10 in] inboard of that door, must conform to the requirements of this standard.

214 The statement below is applicable to the following

incomplete vehicle type if the GVWR is 4536 kg [10,000 lb] or less:

• E-Series Basic (Stripped) Chassis

The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in-van type vehicle. Walk-in vans are exempt from the requirements of Standard 214, Side Impact Protection. See walk-in van denition on page 5.

217 The statements below are applicable to the incomplete

E-Series Van or Wagon when completed as a bus (not school bus):

This vehicle, when completed, will conform to Standard 21 7, Bus Wi ndow R ete nti on and Rel ease, if n o alterations, modications, or replacements are made to the doors, window glazing materials, window mounting systems, or the surrounding door structure as provided by Ford Motor Company.

An y window s, doo rs, ad dit ion al components, or emergency exits added to this vehicle must meet the requirements of this Standard.

217 The statement below is applicable to the Cutaway

when completed as a bus (including school bus):

Conformity with Standard 217, Bus Window Retention and Release, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard other than that the front door windows will comply with the s5.1 requirements of this Standard if no modications, alterations, or replacements are made to the window glazing materials, window mounting system, or the surrounding door structure as provided by Ford Motor Company.

217 Canadian Requirements:

Th e preceding stat eme nts for FMVS S 217 are appropriate compliance representations for CMVSS 217, Bus Emergency Exit and Window Retention and Release, when a vehicle is completed as a Bus (not School Bus) and if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 217 paragraphs (2) and (2.1) are substituted for the reference to FMVSS 217 Section 5.1. When an E-Series Cutaway is completed as a School Bus, Ford Motor Company makes no representation as to conformity to this Standard.

E-SERIES (May, 2004) 39

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 41

219 See combined statements under “212/219” for all

vehicle types.

220 The statements below are applicable to the Cutaway

equipped with the School Bus Prep Package when completed as a school bus:

The Cutaway body structure as manufactured by Ford, does not meet the strength requirements of FMVSS 220, School Bus Rollover Protection; accordingly Ford Motor Company makes no representation as to conformity of the completed vehicle with this Standard.

221 The statements below are applicable to the Cutaway

equipped with School Bus Prep Package when completed as a school bus:

This vehicle when completed, will conform to Standard 221, School Bus Body Joint Strength, if:

• No alterations or modifications are made to the body panel joints as manufactured by Ford Motor Company from the forwardmost point of the windshield rearward.

• The passenger rst row seating reference point is located 762.0 mm [30.00 inch] or more, rearward of the back of the Cutaway body.

Any additional maintenance panels or body panel joints that are added to this vehicle must comply with the requirements of this regulation.

222 The statement below is applicable to the Cutaway

equipped with the School Bus Prep Package when completed as a school bus:

Conformity with Standard 222, School Bus Passenger Seating and Crash Protection, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.

225 The statement below is applicable to all incomplete

vehicle types except Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 225, Child Restraint Anchorage Systems, if:

• No alterations are made to the front passenger seat tether anchorages and access to the anchorages is not restricted, and no alterations are made to the seat assemblies, their anchorages, the oor pan, or oor pan reinforcements, and no seats are added.

225 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Co nformi ty with Standa rd 225, Ch ild Restraint Anchorage Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representations as to conformity with this Standard.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)40

301 Note

The ter ms “body” or “b ody structu re”, in the 301 statements that follow include not only the basic body or body structure but also any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer.

301 INFORMATION

Th e U nloaded Vehi cle Wei ght of the comp let ed vehicle may signicantly affect its capability to meet the requirements of FMVSS 301. Completed vehicles manufactured by Ford Motor Company that are tested to demonstrate complia nce with FMVSS 301 are loaded pursuant to S7.1.6 of the Standard. The test weights of these vehicles compr ise the Unloaded Vehicle Weights including the weights of all available regular production options plus the loads specied by S7.1.6. These test weights are less than the respective designated Gross Vehicle Weight Ratings. In addition to the specic statements below, refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Fuel System information to assist in designing fuel systems and the Second Unit Body Attachment recommendations for information to aid in designing second unit bodies and their attachments to be compatible with E-Series vehicles.

301 In addition to the statements pertaining to particular

incomplete vehicle types which follow on pages 41-47, the statements immediately below, concerning Standard 301 Fuel System Integrity, apply to all incomplete vehicle types to be completed with a GVWR of 4536 kg [10,000 lb] or less or equipped with School Bus Prep Package and completed as a school bus.

• If a fuel line is to be disconnected, refer to the appropriate Ford Service Manual for proper removal and installation procedures.

• When welding near fuel system components, all metallic components must be adequately shielded and protected from heat or weld splatter. All nonmetallic components must be removed.

301 The statements below are applicable to the following

incomplete vehicle types if the vehicle GVWR is 4536 kg [10,000 lb] or less:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 301, Fuel System Integrity, if:

• The following fuel system components, as installed by Ford Motor Company, are not to be removed, relocated, altered, or modied in any way:

– Fuel tank and attachment hardware, including

sending unit, vapor valve, fuel tank shield and in-tank electric fuel pump (all gasoline engine applications), and OBD II pressure transducer

– F uel filler ca p, pipe, hose, an d attachm ent

hardware – Fuel lines, routing, and attachments – Vapor lines and carbon canister – (gasoline engine

application) – Fuel pump – Fuel lter – Fuel water separator fuel filter/primer, fuel line

heater, and injection pump – (diesel engine only) – Fuel shut off switch (Inertia switch)

301 (Continued Next Page)

NOTE: Some incomplete vehicles are equipped with

nylon fuel tubes. In the event that the tubes require repair or replacement, only Ford approved parts or their equivalents should be used.

E-SERIES (May, 2004) 41

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 43

OUTBOARD FRAME REINFORCEMENT

BACK-TO-BAC

CROSSMEMBER

LOWER FRAME FLANGE REINFORCEMENT

OUTBOARD FRAME REINFORCEMENT

FIGURE H – E-SERIES CUTAWAY WITH GASOLINE ENGINE AND SCHOOL BUS PREPARATION PACKAGE

301 (Continued)

• No other alteration or modification made to the incomplete vehicle, as manufactured by Ford Motor Company, and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specied by applicable provisions of Standard 301.†

• The completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table A for E-Series on page 15 corresponding to the incomplete vehicle’s model and wheelbase.

301 The statements below are applicable to the following

incomplete vehicle types if the vehicle GVWR is 4536 kg [10,000 lb] or less:

• Cutaway

• E-Series Cutaway (SRW) with Diesel Engine and School Bus Preparation Package

• E-Series Cutaway (SRW) with Gasoline Engine and School Bus Preparation Package

This vehicle, when completed, will conform to Standard 301, Fuel System Integrity, if:

• The following fuel system components as installed by Ford Motor Company are not removed, relocated, altered, or modied in any way except as specied in the following representations:

– Fuel tank(s) and attachment hardware, including

301 (Continued Next Page)

– Fuel lines, routing, and attachments – Vapor line(s) and carbon canister – (gasoline engine

application) – Fuel pump – Fuel lter – Fuel water separator fuel filter/primer, fuel line

heater, and injection pump – (diesel engine only) – Fuel shut off switch (Inertia switch) – The two Outboard Frame Reinforcements, two

Lower Frame Flange Reinforcements, and two

extra back-to-back crossmembers, all shown above,

and all unique to the gasoline engine School Bus

Package.

• No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301.†

• The completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table A on page 15 corresponding to the model and wheelbase.

sending unit, vapor valve, fuel tank shield, pressure transducer, and in-tank electric fuel pump

– Fuel ller cap(s), pipe(s), hose(s), and attachment

hardware

STATEMENTS OF CONFORMITY

† Temporary removal of the front bumper and front bumper mounting

system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual should not adversely affect compliance of the completed vehicle to Standard

301.

E-SERIES (May, 2004)42

301 (Continued)

• The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows:

– The body is mounted securely and is so designed

that when the completed vehicle is tested in any manner specified by applicable prov is ions o f Standard 301,

(a) body components do not contact any fuel

system component at any time (other than at the points where the fuel system is permanently attached to the body), and,

(b) body deformation or movement relative to

the frame does not cause any fuel system component to be penetrated, disconnected, or otherwise damaged.

– The rear end of the body (excluding the rear bumper)

installed by a subsequent stage manufacturer does not extend beyond (overhang) the rear edge of the vehicle frame or frame extension. Any extension of the vehicle frame must be constructed and attached so as to perform as a continuation of the vehicle frame when the completed vehicle is tested in any manner specied by applicable provisions of Standard 301.

– The fuel ller cap(s), pipe(s), hose(s) and attachment

hardware are installed as shown in Figure I page 44 for E-Series vehicles. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specied by applicable provisions of Standard 301.

301 The statements below are applicable to the following

incomplete vehicle type if the GVWR Is 4536 kg [10,000 lb] or less:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 301, Fuel System Integrity, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this standard.

However, Ford Motor Company has tested completed vehicles incorporating a representative fuel system and frame assembly of a Basic (Stripped) Chassis in accordance with the procedures of Standard 301 at test weights specied by s7.1.6 of the Standard. The tested vehicles met the applicable requirements of Standard

301. Th is vehicl e, when completed , is c apable of compliance with FMVSS 301, if:

• The following fuel system components as installed by Ford Motor Company are not removed, relocated, altered, or modied in any way except as specied in the following representations:

– Fuel Tank and attachment hardware, including

se ndi ng u nit , va por valve, O BD I I pr essure transducer, fuel tank shield, and in-tank electric pump

– Fuel filler cap, pipe, hose(s), and attachment

hardware – Fuel lines, routing, and attachments – Vapor line(s) and carbon canister – Fuel Filter

• No other alteration or modication is made to the incomplete vehicle, as manufactured by Ford Motor Company, and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specied by applicable provisions of Standard 301.†

• The completed E-Series has an Unloaded Vehicle Weight that does not exceed the value designated in Table A on page 15 corresponding to the model, and wheelbase.

E-SERIES (May, 2004) 43

† Temporary removal of the front bumper and front bumper mounting

system during manufacture, and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual, should not adversely affect compliance of the completed vehicle to Standard

301.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 45

• The body installed by a subsequent stage manufacturer

TO BA CK O F CU TAW AY C AB

OU TBO AR D

SU RFA CE

FR AME R AI L

FR ONT O F

VE HIC LE

E- S ER I ES E- 3 50/ 450 CU TAW AY AND BA SIC (S TRI PPE D)

CH A SS I S A FT - OF- AXL E F UEL FI LLE R S YST EM

OF FI LL ER N EC K

TO L OF R EA R AX LE FO

ST RIP PE D CH AS SI S

AL L W .B

. 60 1.4 12 .7 [2 3.7 0. 5]

FU EL TA NK

31 9.

[1 2.5 6]

TO P O F FI LLE R PI PE SU PPO R

40 .2

[1 .58 3

]

RO UTE F IL L AN D VE NT HO SE SO N O LO

SP OTS O CC UR

FU EL TA NK F

IL L P IP E

EX IST IN G 9. 7 DI A. H OL E

(U SED F OR E XH AU S

ON R. H. S ID E

)

N6 116 45 -S 36 M1 0 S EL F- TA PP IN G SC RE

W (A TTA CH T O SO UN D ME TAL O N FR AM E)

N6 111 31 -S 36 M4 SE LF -T AP PI NG

SC REW

SE CUR E WI TH T I

ST RAP S AS R EQ UI RE D

TO VE NT H OS E

9A 09

GR OUN D ST RA

FU EL TA NK

SC REW 3 R EQ íD

TO RQU E TO 2 .1 - 2. 9

18 - 26 I N. -L B.

2641.6 [104.0] [+0.00-2.00] [138 wb]

3149.6 [124.0] [+0.00-2.00] [158 wb]

3606.8 [142.0] [+0.00-2.00] [178 wb]

733.4

[28.875]

(MAX.)

CR ITI CAL C O NT ROL I T EM

NO TES :

TO RQU E A LL WO RM GE A R DRI VE N HO SE CLA MP S T O 2 .9 - 4.3 N M 25 - 38 IN .-L B

[ ] D IME NS ION S A RE IN CHE S

FI LLE R H EI GHT FO R S CH OOL B U S FU EL SYS TE M 4 16. 0 [ 16 .38 ].

CALI FORNI A POIN T Z SEE PAGE 58

and the Ford installed fuel system components are located and mounted as follows:

– The body is mounted securely and is so designed

that when the completed vehicle is tested in any manner specified by applicable prov is ions o f Standard 301,

(a) body components do not cont act any fuel

system component at any time (other than at the points where the fuel system is permanently attached to the body), and,

(b) body deformation or movement relative to

the frame does not cause any fuel system component to be penetrated, disconnected, or otherwise damaged.

• The rear end of the body (excluding the rear bumper) installed by a subsequent stage manufacturer does not extend beyond (overhang) the rear edge of the vehicle frame or frame extension. Any extension of the vehicle frame must be constructed and attached so as to perform as a continuation of the vehicle frame when the completed vehicle is tested in any manner specied by applicable provisions of Standard 301.

• The E-Series Basic (Stripped) Chassis aft-of-axle fuel ller cap, pipe, hose(s), and attaching hardware are installed as shown in Figure I, below. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specied by applicable provisions of Standard 301.

The Basic (Stripped) Chassis is equipped with a Fuel Shutoff Switch. The switch is located on the column support structure for E-Series and must not be relocated, altered, or modied in any way.

301 (Continued on Page 45)

FIGURE I – E-SERIES CUTAWAY AND BASIC (STRIPPED) CHASSIS FUEL FILLER PIPE INSTALLATION

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)44

301 (Continued)

301 The statements below are applicable to the over 4536

kg [10,000 lb] GVWR E-350 DRW and E-450 Cutaway when equipped with Diesel Engine and School Bus Prep Package and completed as a school bus:

This vehicle when completed will conform to Standard 301, Fuel System Integrity if:

• The following fuel components as installed by Ford Motor Company are not removed, altered, or modied in any way except as specified in the following representations:

– Fuel tank and attachment hardware, including

sender unit, vapor valve, and fuel tank shield

– F uel fil ler cap, pipe, hoses, an d at taching

hardware – Fuel pump – Fuel lter – Fuel water separator, fuel filter/primer, fuel line

heater, and injection pump – Fuel shut-off switch (Inertia switch) – The two lower frame brackets on E-350 DRW

• Th e com ple ted vehicle when loa ded to t he requirements of S7.1.6 (c) does not exceed the GVWR or GAWR’s.

• The E-350 DRW and E-450 floor structure of the Second Unit Body and rear bumper are manufactured and installed to the specications found in Figures J1 and J2 on pages 46 and 47.

• The ll hoses, hose clamps, ground strap, and fuel sender unit must be installed to the specication on Figure I, page 44.

301 Canadian Requirements:

The Canadian loading requirements are provided in Section 3.3 of Test Method 301 Fuel System Integrity, revised: February 8, 2001, and should be substituted wherever references to FMVSS 301 Section 7.1.6, loading requirements have been made in the statements of conformity for Standard 301.

302 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

Th is vehicl e, when comp leted , will con form with Standard 302, Flammability of Interior Materials, if no alterations are made to those components covered by the Standard which are installed by Ford Motor Company and all components covered by Standard 302, which are added to the incomplete vehicle by subsequent stage manufacturers meet the ammability requirements of the Standard.

302 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 302, Flammability of Interior Materials, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard. However, Ford Motor Company does represent that the items covered by Standard 302 when provided, are manufactured to conform to the requirements of Standard 302.

1106 Canadian Requirements:

The statements below are applicable to the following

incomplete vehicle types with GVW ratings of 4536 kg [10,000 lb] or less:

• Incomplete E-Series Van or Wagon

• Cutaway

These veh ic le s, when completed, will conform to Standard 1106, Noise Emissions, Section 2, if noise control devices or elements of design are not modied removed or rendered inoperative. Examples of such devices or elements of design are:

• Fender apron absorbers, fender apron barriers, underbody noise shields and acoustic absorption material.

• Engine speed governor or electronic control intended to control maximum engine speed.

• Engine air duct, air intake choke or silencer, air cleaner and air cleaner element.

• Exhaust system components including the catalyst inlet pipe, mufer, outlet pipe, resonator and diffuser.

• Engine cooling fan and cooling fan clutch.

1106 Canadian Requirements:

The statements below are applicable to the following

incomplete vehicle types with GVW ratings of more than 4536 kg [10,000 lb]:

• Incomplete E-Series Van or Wagon

• Cutaway

These veh ic le s, when completed, will conform to Standard 1106, Noise Emissions, Section 4, if noise control devices or elements of design are not modied removed or rendered inoperative. Examples of such devices or elements of design are:

• Fender apron absorbers, fender apron barriers, underbody noise shields and acoustic absorption material.

• Engine speed governor or electronic control intended to control maximum engine speed.

• Engine air duct, air intake choke or silencer, air cleaner and air cleaner element.

• Exhaust system components including the catalyst inlet pipe, mufer, outlet pipe, resonator and diffuser.

• Engine cooling fan and cooling fan clutch.

E-SERIES (May, 2004) 45

† Temporary removal of the front bumper and front bumper mounting

system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual should not adversely affect compliance of the completed vehicle to Standard

301.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 47

FORD PROVI DED ISOL ATORS (6

)

778. 8

[

30.6 6]

12.8 [.50 ]

161. 4

[6.3 5]

25.4

[1.0 0]

TYPI CAL

268.

[

10.5 5]

164. 3

[6.4 7]

147. 8 [5.8 2]

163.

[6.4 5]

2375 .0

[

93.5 ] MINI MUM

FORD PROVI DED

12.0 mm BOL T (6 REQ ’D

)

TORQ UE

162. 1

[6.3 8]

101. 6 [4.0 0]

14.0 x 28.

[.55 x 1.1 0] 2 SL OTS IN ITEM

#12, 13,& 1 4

241.

[9.5 0]

357.

[14. 06]

2438 .4

[96. 00]

50.8

[2.0 0]

228. 6

[9.0 0]

1318 .3

[

51.9 0]

114.

[4.5 0]

EXIS TING S LOT

EXIS TING FRAM E

HOLE S

1/2 BOLT G R5

TORQ UE 95N m 70 ft lb

2 PE R BOLT

1/2 WASHER

(

HARD ENED)

70Nm 52 ft lb

, 1/ 2 NUT GR5

THE FUEL F ILE HOLE IN I TEM #1 5 (FLOOR ) MUST BE 3.0 [.12] LARG ER THE N BASE O F ITEM #16

WHEE LHOUSE

CLEA RANCE

MAY BE REM OVED

TO A CCOMMO DATE

ITEM PART NAME MATERIAL QUANTITY

1 SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. 6.35mm [0.25] HRLC STEEL 1 2 SUPPORT – BODY ISOLATOR TO CROSS SILL R.H. 6.35mm [0.25] HRLC STEEL 1 3 BRACKET – SPACER FOR ISOLATOR SUPPORT 6.35mm [0.25] HRLC STEEL 2 TO FRONT CROSS SILL 4 BRACKET – SPACER FOR ISOLATOR SUPPORT 6.35mm [0.25] HRLC STEEL 2 TO SECOND CROSS SILL 5 SILL – FRONT CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 1 6 SILL – SECOND CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 1 7 SILL – THIRD & FOURTH CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 2 8 GUSSET – CROSS SILL TO OUTER SUPPORT L.H. 1.9mm [0.075] 14 GA. HRLC STEEL 4 9 GUSSET – CROSS SILL TO OUTER SUPPORT R.H. 1.9mm [0.075] 14 GA. HRLC STEEL 4 10 SUPPORT – CROSS SILL OUTER L.H. 3.0mm [0.120] 11 GA. HRLC STEEL 1 11 SUPPORT – CROSS SILL OUTER R.H. 3.0mm [0.120] 11 GA. HRLC STEEL 1 12 BUMPER – REAR 4.7mm [0.187] HRLC STEEL 1 13 BRACKET – BUMPER TO FRAME L.H. 6.35mm [0.25] HRLC STEEL 1 14 BRACKET – BUMPER TO FRAME R.H. 6.35mm [0.25] HRLC STEEL 1 15 FLOOR 1.9mm [0.075] 14 GA. HRLC STEEL 1 16 HOUSING – FUEL FILL NECK 1.9mm [0.075] 14 GA. HRLC STEEL 1

BLIND RIVET FASTENERS

The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength of 3600 lb and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION

Item 5 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr ange – Item 6 to 15 48 Estimated 50.8mm [2.00] stagger frt and rr ange Item 7 to Item 15 47 Estimated 50.8mm [2.00] Centers Item 5 to Items 8 or 9 6 101.6mm [4.00] Centers Item 6 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sill Item 7 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sill Items 8 or 9 to Items 10 or 11 3 on vertical side of item 10 or 11, 1 on bottom ange 3 fasteners are 76.2mm [3.00] Centers Item 16 50.8mm [2.00] Centers

FIGURE J1 – E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)46

WELD SHEET M ETAL

RELIE F AFTER FORMI NG

GUSSE T CROSS SILL TO OUTER SUPPOR T R.H. SHOW

L.H. SYMETRI CALLY OPPOSIT E.

SUPPO RT CRO SS SIL L OUTER L.H. SHOWN. R.H. SYMETRI CALLY OPPOSIT E.

VIEW

24.8

[ 0.98

]

23.1

[ 0.91

]

104.

[ 4.13

]

177.

[ 6.99

]

571.

[ 22.51

]

46.8

[ 1.84

]

1318.

[ 51.90

]

320.0

[ 12.60

]

102.

[ 4.02

]

200.

[ 7.87

]

985.

[ 38.80

]

492.8

[ 19.40

]

TO OF 36.0 DIA H OLE

13.0

[ 0.51

]

DIA 8 HO LES

42.7

[ 1.68

]

[ 0.31

]

49.

[ 1.94

]

134.0

[ 5.28

]

67.0

[ 2.64

]

36.

C L

[ 1.42

]

DIA 2 HO LES

TO OF SILL

13.

[ 0.51

]

DIA 4 HO LES

46.5

[ 1.83

]

28.1

[ 1.11 ]

110.0

[ 4.33

]

37.0

[ 1.46

]

74.0

[ 2.91

]

85.

[ 3.35

]

170.0

[ 6.69

]

SEE VIEW C FOR HOLE DIM ENSION

LOCATION

32.

[ 1.26 ]

125.0

[ 4.92

]

98.0

[ 3.86

]

26.

[ 1.06

]

38.6

[ 1.52

]

34.9

[ 1.37

]

110.0

[ 4.33

]

18.0

[ 0.71

]

48.

[ 1.89 ]

122.0

[ 4.80

]

170.0

[ 6.69

]

40.

[ 1.59

]

172.

[ 6.77

]

138.8

[ 5.46

]

32.6

[ 1.28

]

71.6

[ 3.13

]

36.1

[ 1.42

]

42.7

[ 1.68

]

425.8

[ 16.76

]

134.0

[ 5.28

]

851.

[ 33.53

]

13.0

[ 0.51

]

DIA 8 HO LES

BOTH ENDS OF ITEMS #5, 6, AND 7 CROSS SILLS MUST B E WELDE D COMPL ETELY TO ITEM #10 L EFTSIDE AND I TEM #1 1 RIGHT SIDE. A LL CRO SSSILLS ARE S HOWN WITH OUT SIDE E NDS THAT WILL AC COMMOD ATE A F LUSH F LOOR JOINT WH EN COMPL ETED.

RAI

36.7

[ 1.44

]

13.0

[ 0.51

]

DIA 4 HO LES

M12 BOLT & NUT GC 10. 9 TORQUE 70 Nm 52 ft lb

14.0 [.5 5] DIA HOLE

TRIM WITH 45 ANGL E

TO RE MOVE SH ARP CO RNER

IVM0028

SUPPO RT BOD Y IS0L ATOR TO CROSS SILL L.H.SHO WN. R. H. SYME TRICAL L

OPPOS ITE.

46.2

[ 1.82

]

15.

[ 0.59

]

1303.

[ 51.30

]

1168.

[ 46.00

]

44.5

[ 1.75

]

409.

[ 16.11

]

ON ALL 4 EDGES.

ITEM #3 & #4 ARE WELD ED TO ITEM #1 OR #2

552.4

[

21.78]

VIEW

111.1

[4.37]

VIEW

95.5

[ 3.76

]

14.0

[ 0.55

]

DIA 3 HO LES

60.4

[ 2.38

]

102.

[ 4.02

]

56.

[ 2.21

]

FIGURE J2 – E-SERIES DIESEL SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE

E-SERIES (May, 2004) 47

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 49

CANADIAN VEHICLES

(Vehicles to be completed for sale or use in Canada)

VEHICLE IDENTIFICATION

Refer to the Vehicle Description section of this manual on page 7, for additional information. Incomplete vehicles produced by Ford Motor Company require, for certain applications, optional Prep Packages or trim codes which are listed on the Completed Vehicle Types charts on page 8.

DAYTIME RUNNING LAMP (DRL)

Compliance representations for CMVSS 108, Lighting and CMVSS 108.1, Headlamps, are on page 19. The following items are also required for CMVSS 108 and 108.1 compliance:

• The DRL module circuits are not to be altered.

• DRL module is not to be repositioned.

• The E-Series Basic (Stripped) Chassis is not to be equipped with more than two headlamps when equipped with a DRL module as provided by Ford Motor Company.

CANADIAN RADIO FREQUENCY INTERFERENCE (RFI) INFORMATION

All vehicles powered by spark ignition engines (e.g.: gasoline, natural gas, or propane engines) and manufactured in Canada or for sale or use in Canada are subject to the Canadian “Regulations for the Control of Interference to Radio Reception” per Interference-Causing Equipment Standard (ICES-002) and applicable test method according to “CAN/CSA-C108.4-M92”. Violation of these regulations is punishable by ne or imprisonment. This Ford-built incomplete vehicle (if other than a Basic (Stripped) Chassis) was designed and manufactured to be capable of meeting the regulatory requirements or such modications thereof as may have been authorized by the Department of Communications. However, because Ford Motor Company has no control over how this incomplete vehicle is completed by subsequent stage manufacturers, Ford Motor Company does not represent that the completed vehicle incorporating the Ford-built components will comply with applicable requirements.

The following information is supplied to subsequent stage manufacturers to help them avoid increasing the RFI emissions of this vehicle in the course of completing it.

For any completed vehicle, additional measures may be needed to adequately suppress RFI emissions. Affected components could include spark plugs, ignition wires, ignition coils, ground straps, ignition component shields, accessory drive belts, instrument voltage regulator suppressor assembly, and ignition coil suppressor assembly.

More specically:

• All components required to suppress RFI emissions, which are removed during service, repair, or completion of the vehicle, must be reinstalled in the manner in which they were installed by Ford Motor Company.

• Shields on ignition coils must remain installed.

• Replacement spark plugs, ignition wires, and ignition coils must be equivalent in their RFI suppression properties to original equipment.

• Electrical grounds on all components must be retained.

• Metallic components installed on the body or chassis must be grounded to the chassis.

• Electrical circuits added to the vehicle must not be installed near the high voltage ignition components.

• Only “static conductive” accessory drive belts should be used. Fan, water pump, power steering, and other belts should be of the OEM type or equivalent that will not build up a static electrical charge.

• Engine compar tment wiring must not be rerouted in any manner.

• The Powertrain Control Module (PCM) must not be relocated from the position as installed by Ford Motor Company.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)48

EMISSION CERTIFICATION INFORMATION

CAUTION:

U.S.:

20 05 MO DEL YEAR V EHI CLE S AR E EM ISSION CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS OF THE UNITED STATES. FOR EXAMPLE, VEHICLES

CERTIFIED AND LABELED FOR SALE IN CALIFORNIA CAN NOT BE SOLD IN THE STATES THAT REQUIRE FEDERALLY CERTIFIED VEHICLES AND VEHICLES CE RTIFIED TO FE DER AL STANDARD S C AN NOT BE SOLD IN STATES THAT REQUIRE CALIFORNIA CERTIFIED VEHICLES. IT IS THE SUBSEQUENT STAGE

MANUFACTURER’S RESPONSIBILITY TO PURCHASE A VEHICLE CERTIFIED FOR THE STATE/AREA IN WHICH THE VEHICLE WILL BE SOLD. EPA HAS STATED THAT UNDER CERTAIN CIRCUMSTANCES THEY WILL NOT ENFORCE THESE REQUIREMENTS. FOR FURTHER GU IDAN CE CON SULT EPA’S “ POLIC Y ON CROSS BORDER SALES OF CALIFORNIA VEHICLES.”

CANADA:

IF TH E COMPL ETED VEH ICLE IS I NTENDED FOR SALE OR USE IN CANADA, THE INTERMEDIATE OR FINAL STAGE MANUFACTURER MUST INSURE THAT THE INCOMPLETE VEHICLE IS ORDERED THROUGH A CANADIAN DEALER OR IS ORDERED FROM FORD MOTOR COMPANY WITH THE APPROPRIATE CANADIAN MARKET OPTION CODE. FAILURE TO DO SO MAY RESULT IN AN INCOMPLETE VEHICLE THAT IS BUILT WITH AN EMISSIONS SYSTEM AND LABELING THAT ARE NOT IN COMPLIANCE WITH THE REQUIREMENTS OF THE CANADIAN ENVIRONMENTAL PROTECTION ACT.

MEDIUM DUTY PASSENGER VEHICLES (MDPV)

EPA has ado pte d s epa rat e e mis sio ns sta ndards and requirements for MDPVs beginning in 2005. A MDPV is dened as a heavy-duty vehicle with a GVWR under 10,000 lbs. designed primarily for the transportation of persons (with seating for up to 12 persons, or up to 9 persons rearward of the drivers seat). E-Series vehicles ordered with the RV-Prep package are certied to MDPV standards and may be converted to MDPVs without requiring additional emission certication.

FRONTAL AREA AND WEIGHT RESTRICTIONS:

All 4.6L and some 5.4L E-Series Vans and Wagons are certied to complete light duty <3856 kg [8500 lb] protocol and require vehicle weight and frontal area restrictions. Complete 5.4L and

6.8L Vans and Wagons certied to California >3856 kg [8500 lb] Medium Duty Vehicle (MDV) protocol also have vehicle weight and frontal area restrictions. Modiers that add weight to a vehicle or increase the frontal area of a light-duty/MDV vehicle prior to sale and delivery to the ultimate purchaser, may be required to re-certify the vehicle for compliance with applicable federal or California emission standards. Refer to guidance under “Emission Control Modications” in the Ford “Body Builders Layout Book”. Starting in 2005, some heavy-duty incomplete vehicles are certied using chassis cer tification protocol and will require vehicle weight and frontal area restrictions (to retain emission certication). If your

IMPORTANT:

For purposes of Government Regulation, a body builder, installer, or any subsequent manufacturer may be considered a manufacturer.

IMPORTANT:

It is the responsibility of the body builder, installer, or subsequent stage manufacturer to ensure that the maximum completed vehicle curb weight and frontal area specied by Ford are not exceeded. If these restrictions are exceeded, or if the vehicle is modied such that it will not comply with appl icable emissi on standa rds through out its usefu l life, t he b ody buil der, installer, or subsequent stage manufacturer will be considered a manufacturer for purposes of complying with U.S. Federal, California, or Canadian exhaust and evaporative emission requirements, and Federal fuel economy standards, labeling, and cer tain other requirements.

vehicle is affected, the frontal area and unloaded vehicle weight information will be found on the VECI label, which is located in the engine compartment. Incomplete vehicles with engines certied using heavy-duty engine protocol are not limited by weight and frontal area restriction for exhaust emissions.

It is important that the nal stage manufacturer observe vehicle restrictions from vehicle safety requirements, etc., which are located elsewhere in this manual. Additional emissions certication information is contained in the Ford Truck Body Builders Layout Book for the model year and type of this incomplete vehicle.

HIGH ALTITUDE REQUIREMENTS

United States Environmental Protection Agency regulations for the 2005 model year do not contain unique emission certification requirements for trucks that will be sold or delivered to customers for principal use above 1,219 m [4,000 ft.].

EMISSION CONTROL HARDWARE

Any body builder, installer, or subsequent stage manufacturer must also assure that all emission control hardware furnished with incomplete vehicles is on the vehicle and is operational and that applicable instru ct ions for incor po rati ng such hardware into the completed vehicle’s electrical or mechanical systems are strictly followed.

Fur ther, to avoid any question of certification coverage, approval of any modication or use of an engine or vehicle which may render inoperative any of the emission control compon ents must be obtained from th e United States Environmental Protection Agency by the manufacturer making such modication or use prior to distribution, sale, offering for sale, introduction, or delivery for introduction of the subject vehicle into U.S. commerce. Additionally, the manufacturer making such modication or use must obtain approval from the California Air Resources Board if the new vehicle will be delivered for sale or use in the State of California.

UNLEADED GASOLINE LABEL

Regulations no longer require the manufacturer to affix permanent labels reading “Unleaded Gasoline Only” or “Unleaded Fuel Only” to vehicles destined for sale in the United States or Canada. Such labels may however be required for vehicles sold into other markets. It is the responsibility of the body builder, installer, or any subsequent manufacturer to properly label vehicles for the market in which they are sold.

E-SERIES (May, 2004) 49

EMISSION CERTIFICATION INFORMATION

E-SERIES (May, 2004) 51

EXTERIOR NOISE

New vehicles which have a gross vehicle weight rating in excess of 4536 kg [10,000 lb], include a partially or wholly enclosed operator’s compartment, and are manufactured for use in the United States, must comply with U.S. Environmental Protection Agency’s exterior noise emission regulations for medium and heavy trucks (40 CFR Part 205, Subpart B) which establish a noise emission limit of 80 dB (A).

However, the Basic (Stripped) Chassis as built by Ford is too incomplete to constitute a regulated vehicle and Ford does not represent that it complies with those regulations. With respect to the Basic (Stripped) Chassis, it is the responsibility of the subsequent stage manufacturer of that vehicle at the time it rst conforms to the regulatory denition of “vehicle” to comply with the requirements imposed upon manufacturers by these regulations.

TAMPERING WITH NOISE CONTROLS

Federal law prohibits the removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into such vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use. Federal Law also prohibits the use of such vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

• Removal of fender apron absorbers, fender apron barriers, underbody noise shields, or acoustical absorpti ve material.

• Removal of or rendering inoperative the engine speed governor so as to allow e ngine speed to exceed manufacturer’s specications.

• Removal or modication of air duct, air intake choke or silencer, air cleaner, or air cleaner element.

• Removal of, or rendering inoperative, exhaust system components including the catalyst inlet pipe, mufer, outlet pipe, resonator, or diffuser.

• Removal of the fan shroud. Removal of or rendering inoperative the fan clutch.

New vehicles manufactured for sale in Canada must comply with applicable provisions of Canada Motor Vehicle Safety Standard 1106, Noise.

Additional noise emissions information is contained in the Ford

Truck Body Builders Layout Book.

WARRANTY AND MAINTENANCE

A copy of the appropriate Ford Truck Owners Guide and Warranty Facts Booklet must be installed in every vehicle

prior to sale to the ultimate purchaser in order to provide emission systems warranty information and maintenance schedules. It also provides, where required by EPA noise control regulations for vehicles having GVWR over 4536 kg [10,000 lb], noise emissions warranty information, instructions for maintenance, use, and repair of vehicle noise emission control systems, a maintenance record format, and list of prohibited tampering acts.

EVAPORATIVE EMISSIONS

All 2005 Federal light and heavy duty trucks and all California vehicles wi th gasoline engines are requir ed to comply with evaporative emissions requirements established by the Environmental Protection Agency or the California Air Resources Board. Production fuel systems supplied on incomplete 2005 model year trucks manufactured by Ford Motor Company comply with these requirements. If the

subsequent stage manufacturer adds to or modies the fuel system in any manner, it becomes the responsibility of the modier to assure compliance with the applicable regulations. Refer to the Design Recommendation section of

the Ford Truck Body Builders Layout Book, for additional Fuel System Evaporative Emissions information.

MALFUNCTION INDICATOR LIGHT (MIL)

Th e “ Mal fun cti on Indicato r L igh t” is u sed to indicate malfunctions of the Electronic Engine Control System and certain emissions-related components. For all incomplete vehicles, except Basic (Stripped) Chassis (which is not equipped with an instrument panel), it is Ford installed and operational.

The E-Series Basic (Stripped) Chassis vehicles, has the warning light installed in the instrument cluster, which is shipped in the dunnage box. If an alternate instr ument cluster is utilized, the nal stage manufacturer must install an operational light in the instrument cluster. This light must glow amber and display the message “Malfunction Indicator Light (MIL)”. It should be recognized that this light is a requirement of emission certication.

OZONE DEPLETING SUBSTANCE (ODS)

The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identied with a “clearly and conspicuously attached label.”

Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2005 Ford Truck incomplete vehicles will not have Class I ODS content.

Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product war ning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment.

EMISSION CONTROL INFORMATION LABEL

To meet United States Environmental Protection Agency regulations, the Important Vehicle Infor mation (tune-up and fuel tank capacity) labels must be afxed in the engine compartment in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be afxed to any equipment that is easily detached from the vehicle.

When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already afxed or to be afxed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii), as applicable.

EMISSION CERTIFICATION INFORMATION

E-SERIES (May, 2004)50

CALIFORNIA FUEL VAPOR RECOVERY

California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fill pipe. Fuel filler pipes installed per Figure I on page 44 will comply with the “Specications For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” (Figure I on page 44 illustrates a typical point Z). The cylindrical zone uses the axis described above, starts at the outer most surface of the Ford supplied fuel ller housing, and projects outward (away from the frame). The fuel pipe housing component is shown on the referenced gures and is attached to the aftermarket body via 3/16 inch diameter rivets.

CALIFORNIA MOTOR VEHICLE EMISSION CONTROL LABEL

To meet California emission cer tification regulations, the Emission Control Information (tune-up) label must be welded, riveted, or otherwise permanently attached to an area within the engine compartment or to the engine in such a way that it will be readily visible to the average person after installation of the engine in a vehicle. In selecting an acceptable location, the manufacturer shall consider the possibility of accidental damage (e.g., possibility of tools or sharp instruments coming in contact with the label). The label shall be afxed in such a manner that it cannot be removed without being destroyed or defaced, and shall not be afxed to any part which is likely to be replaced during the vehicle’s useful life. For motor vehicles rated at 6350 kg [14,000 lb] GVWR or less, the label shall not be afxed to any equipment which is easily detached from the vehicle. As used in these specications, readily visible to the average person shall mean that the label shall be readable from a distance of 460 mm [18 in] without any obstructions from vehicle or engine parts (including all manufacturer available optional equipment), except for exible parts, (e.g., vacuum hoses, ignition wires). Alternately, information required by these specications to be printed on the label shall be no smaller than 8 point type size provided that no vehicle or engine parts (including all manufacturer available optional equipment), except for exible parts that can be moved out of the way without disconnection, obstruct the label.

Completed vehicles for retail sale in California require a machine-readable Vehicle Identication Number (VIN) barcode label made of paper, plastic, metal, or other permanent material which shall be afxed in a readily visible location to either the door-latch post next to the driver’s seating position, the door edge that meets this door-latch post, or above the instrument panel in a location clearly visible through the lower left corner of the windshield.

• All incomplete vehicles except Basic (Stripped) Chassis type vehicles will conform to this standard.

• Basic (Stripped) Chassis type vehicles:

Conformity with CARB Motor Vehicle Emission Control

Label specications for VIN label is not substantially affected by the design of this incomplete vehicle. Accordingly, Ford Motor Company makes no representation as to conformity with this requirement.

For the Vehicle Emission Control (VEC) and VIN labels, sufcient clearance shall be provided to use a non-contact barcode Reading Wand. For the tune-up label and vacuum hose routing diagram label, the label and any adhesives used shall be designed to withstand typical vehicle environment conditions in the area where the label is attached for the vehicle’s total expected life. Typical vehicle environmental conditions shall include, but are not limited to, exposure to engine lubricants and coolants (e.g., gasoline, motor oil, brake uids, water, ethylene glycol), under hood temperatures, steam cleaning, and paints or paint solvents.

RADIO FREQUENCY INTERFERENCE (RFI)

The ignition system on your vehicle (if other than a Basic (Stripped) Chassis) has been designed to be capable of compliance with RFI requirements established by the Canadian government. However, because Ford Motor Company has no control over how an incomplete vehicle is completed by subsequent stage manufacturers, Ford Motor Company does not represent that the completed vehicle incorporating the Ford-built components will comply with those requirements. Any ignition system component (i.e.: spark plugs, ignition wiring, coil suppressor assembly, etc.) that is replaced should be replaced by the same Ford Motor Company part number or equivalent to maintain RFI suppression.

While there are currently no RFI regulations in the United States specically applicable to automotive ignition systems, all Ford Motor Company trucks built with an ignition system use the same or equivalent components to those supplied on Canadian vehicles.

Ford Motor Company recommends that all ignition system service be performed at a Ford authorized service facility to help hold RFI emissions levels to a minimum.

Additional RFI information is contained on page 48 of this manual.

Devices that emit radio frequency (RF) energy such as AM/FM radios, mobile telecommunications systems (two-way radios, telephones), and radio controlled security systems are subject to the rules and regulations of the Federal Communications Communication (FCC), including 47 CFR Parts 2 and 15. Any such system installed in a vehicle should comply with those rules and should be installed only by a qualied technician. In addition, to ensure continued compliance with the FCC’s regulations, RF devices must not be modied or changed in a manner not expressly approved by Ford Motor Company Mobile Communication Systems. RF devices particularly, if not properly installed, may adversely affect the operation of the vehicle. For example, such systems when operated may cause the engine to stumble or stall. In addition, such systems themselves may be damaged or their operation affected by the operation of the vehicle. (Citizens Band [CB] transceivers, garage door openers, and other transmitters whose power output is 5 watts or less, ordinarily will NOT affect vehicle operation.)

Because Ford Motor Company has no control over the operation or manufacture of such systems or their installation, Ford Motor Company cannot assume responsibility for any adverse effects or damage if this equipment is used.

E-SERIES (May, 2004) 51

EMISSION CERTIFICATION INFORMATION

SUPPLEMENTS

E-SERIES (May, 2004)52

REFERENCE INFORMATION

FORD TRUCK BODY BUILDERS LAYOUT BOOK

Throughout this manual you will nd references to information found in the Ford Truck Body Builders Layout Book. Additional Design Recommendations and specications

are also provided to assist subsequent stage manufacturers in completing chassis cab and incomplete vehicles. To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM’s or books please visit our website at www.eet.ford.com/truckbbas. Under Publications select Body Builders Order Forms. All dealer requests can be handled online. All other U.S. orders should be faxed to (734) 713-2971. Canadian orders should be faxed to (905) 670-0844.

FORD SERVICE PUBLICATIONS

Many Ford Service Publications pertain to a specic Model Year and vehicle types. The following publications are a few of many manuals which are available from Helm Incorporated; call: 1-800-782-4356

• Ford Truck Shop Manuals

• Ford Towing Manual

• Ford Electrical & Vacuum Trouble Shooting Manual

• Ford Wiring Diagram

FORD TRUCK BODY BUILDER ADVISORY SERVICE

The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. Call 1-877-840-4338 or e-mail bbasqa@ford.com for assistance or Fax inquiries to (313) 594-2633 accompanied with a cover sheet indicating “Attention to: Ford Truck Body Builder Advisory Service,” along with your name, address and telephone number.

E-SERIES (May, 2004)

REFERENCE INFORMATION

FORD MOTOR COMPANY

THE AMERICAN ROAD

DEARBORN, MI 48121

FORD MOTOR COMPANY OF CANADA LIMITED

THE CANADIAN ROAD

OAKVILLE, ONTARIO L6J 5E4

Ford 5C2S-19A268-AA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual