Ford 5.00E+04 - Manual

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...

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 ...

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...

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...

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...

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 ...

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 ...

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 ...

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 ...

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...

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...

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...

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...

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 ...

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...

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 ...

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...

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 ...

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...

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...

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 ...

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...

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 ���������������������������������������������� ������������������������������������������������ ����������������������������������������� ������...

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...

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...

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 ...

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 ...

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...

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...

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[...

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...

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...

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...

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 ...