Ford 5C2S-19A268-AA - Manuals

Page 4 - local requirements not detailed in this manual.; UNITED STATES AND CANADIAN VEHICLES; INTRODUCTION

E-SERIES (May, 2004) 2 E-SERIES (May, 2004) 3 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 final stage vehicle manufacturers...

Page 5 - TABLE OF CONTENTS

E-SERIES (May, 2004) 2 E-SERIES (May, 2004) 3 TABLE OF CONTENTS DEFINITIONS .................................................................................... 4-5 GENERAL INFORMATION .................................................................... 6 Directions ....................................

Page 6 - Bus; DEFINITIONS

E-SERIES (May, 2004) 4 E-SERIES (May, 2004) 5 DEFINITIONS The following definitions are from Title 49, Code of Federal Regulations, Parts 567.3, 568.3 and 571.3 where noted. Canadian definitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company de...

Page 7 - Incomplete Vehicle

E-SERIES (May, 2004) 4 E-SERIES (May, 2004) 5 DEFINITIONS 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 syst...

Page 8 - DIRECTIONS; Ford Truck Body Builders Layout Book.; GENERAL INFORMATION

E-SERIES (May, 2004) 6 E-SERIES (May, 2004) 7 GENERAL INFORMATION 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 ...

Page 9 - VEHICLE DESCRIPTION; INCOMPLETE VEHICLE MANUAL COVER; INCOMPLETE VEHICLE MANUFACTURED BY

E-SERIES (May, 2004) 7 VEHICLE DESCRIPTION VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER The cover of this manual identifies the three incomplete vehicle confi gurations for which compliance representations are contained in this manual. Also, a label is affi xed to the cover which includes the...

Page 10 - COMPLETED VEHICLE TYPES; Ford Motor Company makes no representation that the; COMPLETED VEHICLES

E-SERIES (May, 2004) 8 E-SERIES (May, 2004) 9 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-3...

Page 11 - STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 8 E-SERIES (May, 2004) 9 STATEMENTS OF CONFORMITY 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 t...

Page 12 - 02 The statements below are applicable to all incomplete

E-SERIES (May, 2004) 10 E-SERIES (May, 2004) 11 STATEMENTS OF CONFORMITY 102 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 102, Transmission Shift Lever Sequence, Star ter I n t e r l o ...

Page 13 - Ford Source Book; Location

E-SERIES (May, 2004) 10 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 103 The statement below is applicable to all incomplete vehicle ...

Page 14 - 05 The statements below are applicable to the following; HORIZONTAL CENTER OF GRAVITY; Wheelbase; Vehicle; EQUATION A; CG; CG; rb; x WB; P x CG; WB; EQUATION B; = the minimum horizontal center of gravity of the

E-SERIES (May, 2004) 12 E-SERIES (May, 2004) 13 STATEMENTS OF CONFORMITY 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 ...

Page 15 - EQUATION C; EQUATION D

E-SERIES (May, 2004) 12 E-SERIES (May, 2004) 13 STATEMENTS OF CONFORMITY 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 ...

Page 16 - Required for

E-SERIES (May, 2004) 14 E-SERIES (May, 2004) 15 STATEMENTS OF CONFORMITY FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES L † = Horizontal distance in inches between the SUB center of gravity and the of the front axle. P = Passenger load (See E-Series Pas...

Page 17 - TABLE A; E-250 Regular and Extended Van; TABLE B; Minimum unloaded vehicle weight for cutaways completed as

E-SERIES (May, 2004) 14 E-SERIES (May, 2004) 15 STATEMENTS OF CONFORMITY 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 Wei...

Page 18 - TABLE C; TABLE F; TABLE E; Horizontal distance from front wheel to front

E-SERIES (May, 2004) 16 E-SERIES (May, 2004) 17 STATEMENTS OF CONFORMITY TABLE C CG hl = 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 13...

Page 20 - Ford Truck Body Builders Layout Book

E-SERIES (May, 2004) 18 E-SERIES (May, 2004) 19 STATEMENTS OF CONFORMITY 108 The statements below are applicable to the following incomplete vehicle type: • Cutaway This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices, and Associated Equipment, if all the required li...

Page 23 - = the minimum horizontal center of gravity of the SUB

E-SERIES (May, 2004) 20 E-SERIES (May, 2004) 21 STATEMENTS OF CONFORMITY 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 ...

Page 24 - r b

E-SERIES (May, 2004) 22 E-SERIES (May, 2004) 23 • The horizontal center of gravity for the SUB is: – At or forward of the rear 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, w...

Page 25 - Ford

E-SERIES (May, 2004) 22 E-SERIES (May, 2004) 23 STATEMENTS OF CONFORMITY 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 ...

Page 28 - The Headliner Plane is defined on Figure G3 page 36, for vehicles

E-SERIES (May, 2004) 26 E-SERIES (May, 2004) 27 STATEMENTS OF CONFORMITY 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 Fig...

Page 29 - 08 The statements below are applicable to the incomplete; The Headliner Plane is defined on Figure G3 page 36, for E-Series

E-SERIES (May, 2004) 26 E-SERIES (May, 2004) 27 STATEMENTS OF CONFORMITY • The Air Bag Supplemental Restraint System as originally installed (see Figure E on page 33), is not removed, relocated, altered, or modified in any way. • T h e A i r B a g S u p p l e m e n t a l R e s t r a i n t S y s t e ...

Page 30 - 08 The statements below are applicable to the following

E-SERIES (May, 2004) 28 E-SERIES (May, 2004) 29 STATEMENTS OF CONFORMITY • No compressible material is installed between front seat assembly and the floor pan. • No additional components or modifications are made to the areas defined as the Occupant Protection Zone shown in Figure D on page 32. • Th...

Page 32 - FIGURE A – E-SERIES FRONT SEAT RESTRAINT SYSTEM

E-SERIES (May, 2004) 30 E-SERIES (May, 2004) 31 STATEMENTS OF CONFORMITY CRITICAL CONTROL ITEM VIEW A A VIEW B B A VIEW A CRITICAL CONTROL ITEM FRONT OF VEHICLE FRONT OF VEHICLE 3C24-15602B82ADJ. ASY. PANEL ASY.UPPER F65B-15602B90COVER ASY. 3C24-1560262COVER ASY.1 REQ’D. EA. SIDE N806773-S190NUT TOR...

Page 33 - FIGURE B – E-SERIES FRONT SEAT INSTALLATION

E-SERIES (May, 2004) 30 E-SERIES (May, 2004) 31 STATEMENTS OF CONFORMITY FIGURE B – E-SERIES FRONT SEAT INSTALLATION POWER L.H. SHOWN SEAT ASY. N802351-S424STUD 2 REQ’D. 2C24-1561701-A POWER TRACK A FRT. ST. 56912-S58SCREW 4.2 x 19TAPPING N800937-S424NUT & WASHER ASY. 2 REQ’D.TORQUE 55.0 8.3 Nm ...

Page 34 - FIGURE D – E-SERIES OCCUPANT PROTECTION ZONE; (SEAT POSITION IS AT THE MIDPOINT

E-SERIES (May, 2004) 32 E-SERIES (May, 2004) 33 STATEMENTS OF CONFORMITY FIGURE D – E-SERIES OCCUPANT PROTECTION ZONE SRP INFORMATION POINT A (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 (V...

Page 35 - FIGURE E1 – E-SERIES SUPPLEMENTAL RESTRAINT; FIGURE E2 – E-SERIES RESTRAINT CONTROL MODULE

E-SERIES (May, 2004) 32 E-SERIES (May, 2004) 33 FIGURE E1 – E-SERIES SUPPLEMENTAL RESTRAINT SYSTEM (Air Bags, Sensors, and Wiring) STATEMENTS OF CONFORMITY �� ...

Page 36 - SECTION BB

E-SERIES (May, 2004) 34 E-SERIES (May, 2004) 35 STATEMENTS OF CONFORMITY CUT LINE SECTION BB CUT LINE CUT LINE SECTION CC SECTION DD CUT LINE CUT LINE SECTION AA B A FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW...

Page 37 - SECTION EE

E-SERIES (May, 2004) 34 E-SERIES (May, 2004) 35 STATEMENTS OF CONFORMITY E F FRONT OF VEHICLE THE SPOTWELDS ( X ) INTHIS AREA MUST REMAININTACT. G NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY. [ ] DIME...

Page 38 - FIGURE G3 – ROOF PANEL REMOVAL AREA – E-SERIES

E-SERIES (May, 2004) 36 E-SERIES (May, 2004) 37 STATEMENTS OF CONFORMITY FIGURE G3 – ROOF PANEL REMOVAL AREA – E-SERIES END OF ROOF EXTENDED VAN END OF ROOF EXTENDED VANOR WAGON REGULAR VAN NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. [ ] DIMENSIONS ARE INCHES CL OUTER EDGEOF TROUGH ...

Page 40 - Temporary removal of the front bumper and front bumper mounting

E-SERIES (May, 2004) 38 E-SERIES (May, 2004) 39 STATEMENTS OF CONFORMITY 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 ...

Page 44 - 01 The statements below are applicable to the following

E-SERIES (May, 2004) 42 E-SERIES (May, 2004) 43 STATEMENTS OF CONFORMITY 301 (Continued) 301 (Continued Next Page) † 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...

Page 46 - C H A S S I S A F T - O F - A X L E F U E L F I L L E R S Y S T E M

E-SERIES (May, 2004) 44 E-SERIES (May, 2004) 45 STATEMENTS OF CONFORMITY • 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 teste...

Page 48 - FIGURE J1 – E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE; ITEM; BLIND RIVET FASTENERS; PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION

E-SERIES (May, 2004) 46 E-SERIES (May, 2004) 47 STATEMENTS OF CONFORMITY FIGURE J1 – E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE 8 3 9 11 12 8 1 9 2 7 9 4 16 FORD PROVIDEDISOLATORS (6) 14 13 10 778.8 [30.66] 12.8[.50] 161.4[6.35] 5 9 6 8 7 25.4 [1.00] TYPICAL 268.0 [10.55] 164.3[6.47] 147.8[...

Page 49 - VIEW C; VIEW

E-SERIES (May, 2004) 46 E-SERIES (May, 2004) 47 STATEMENTS OF CONFORMITY FIGURE J2 – E-SERIES DIESEL SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE 9 10 3 5 6 7 WELD SHEET METAL RELIEF AFTER FORMING GUSSET CROSS SILL TO OUTER SUPPORT R.H. SHOWN L.H. SYMETRICALLY OPPOSITE. SUPPORT CROSS SILL OUTER L.H. S...

Page 50 - CANADIAN VEHICLES; VEHICLE IDENTIFICATION

E-SERIES (May, 2004) 48 E-SERIES (May, 2004) 49 STATEMENTS OF CONFORMITY 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 M...

Page 51 - incomplete; EMISSION CERTIFICATION INFORMATION

E-SERIES (May, 2004) 48 E-SERIES (May, 2004) 49 EMISSION CERTIFICATION INFORMATION CAUTION:U.S.: 2 0 0 5 M O D E L Y E A R V E H I C L E S A R E E M I S S I O N CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS OF THE UNITED STATES. FOR EXAMPLE, VEHICLES CERTIFIED AND LABELED FOR SALE IN CALIFORNIA CAN N...

Page 54 - SUPPLEMENTS

Page 55 - FORD TRUCK BODY BUILDERS LAYOUT BOOK; Ford Truck; FORD SERVICE PUBLICATIONS; REFERENCE INFORMATION

REFERENCE INFORMATION FORD TRUCK BODY BUILDERS LAYOUT BOOK Throughout this manual you will find references to information found in the Ford Truck Body Builders Layout Book . Additional Design Recommendations and specifications are also provided to assist subsequent stage manufacturers in completing ...