Ford E-SERIES 2005 Incomplete Vehicle Manual
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Ford E-SERIES 2005 Incomplete Vehicle Manual

Ford E-SERIES 2005 Incomplete Vehicle Manual

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INCOMPLETE VEHICLE MANUAL
Incomplete Vehicle Types
For This Manual
INCOMPLETE
E-SERIES
VANS &
WAGONS
E-SERIES
CUTAWAY
E-SERIES
BASIC
CHASSIS
DO NOT DESTROY: THIS MANUAL IS REQUIRED BY
LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY
THE FINAL STAGE MANUFACTURER.
2005
E-SERIES
May, 2004
5C2S-19A268-AA
Ð

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  • Page 1 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 Ð...

  • Page 2: Table Of Contents

    U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS (APPLICATION BY VEHICLE TYPE) Bus (Not Truck Truck Standard School School (Not (Walk-in Number Title of Standard Bus) Walk-In Van) Van) Equip. Control Location, Identification and Illumination Transmission Shift Lever Sequence, Starter Interlock & Transmission Braking Effect Windshield Defrosting &...

  • Page 3: U.s. & Canada Motor Vehicle Safety Standards

    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 Number Title of Standard Bus) Walk-In Van) Van) Equip. School Bus Rollover Protection School Bus Body Joint Strength School Bus Passenger Seating and Crash Protection Child Restraint Anchorage Systems (U.S.
  • Page 4 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 affixed to a vehicle.
  • Page 5 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 Identification ................ 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...

  • Page 6: Definitions

    Canadian definitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company definitions are for the purpose of this manual only. Some terms are followed by an abbreviation that is used throughout this manual.

  • Page 7: Definitions

    SAE J826 permits a person to enter the vehicle without stooping. This (May 1987). definition 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.

  • Page 8: General Information

    Throughout this manual you will find references to information representations for a particular safety standard. found in the Ford Truck Body Builders Layout Book. Additional Compliance statements provided in this manual are of Design Recommendations and specifications are also provided...

  • Page 9: Vehicle Description

    INCOMPLETE VEHICLE LABEL and the optional prep packages or trim codes that may be required by Ford Motor Company if final stage manufacturers All E-Series incomplete vehicles manufactured by Ford Motor wish to rely on the Statements of Conformity or, in some cases, Company will have an incomplete vehicle label affixed to the preserve the Ford Motor Company new vehicle warranty.

  • Page 10: Completed Vehicle Types

    (1) Ambulance Prep Package IMPORTANT: (2) School Bus Prep Package Ford Motor Company makes no representation that the - E-350 available on 9600 lb GVWR Single Rear Wheels (SRW), completed vehicle types listed above are the only vehicle and 11,500 lb GVWR Dual Rear Wheels (DRW) only types appropriate for the incomplete vehicles listed.

  • Page 11: Statements Of Conformity

    The statements provided for each safety standard number are appropriate compliance representations for each Canadian safety standard number if this incomplete vehicle, identified 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.

  • Page 12: 102 Transmission Shift Lever Sequence, Starter

    102 The statements below are applicable to all incomplete 102 The statements below are applicable to the following vehicle types except the Basic (Stripped) Chassis: incomplete vehicle type: This vehicle, when completed, will conform to Standard • E-Series Basic (Stripped) Chassis 102, Transmission Shift Lever Sequence, Starter This vehicle, when completed, will conform to Standard Interlock, and Transmission Braking Effect, if no...

  • Page 13: 105 Hydraulic And Electric Brake Systems

    • Service or parking brake pedal assembly operation required for center of gravity calculations are available must not be restricted by any alteration or added in the Ford Source Book. See your local Ford Dealer components. and refer to appropriate model year and specific vehicle •...
  • Page 14 Table E. – Suspension ride height or spring rate – Wheelbase • Any removal of a Ford body or chassis component is accompanied by the addition of equal weight. • The maximum GAWRs and GVWR, as identified on...
  • Page 15 • Any removal of a Ford body or chassis component is accompanied by the addition of equal weight. E-SERIES PASSENGER LOAD •...
  • Page 16 FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES L† = Horizontal distance in inches between the SUB = Weight of the vehicle (chassis and cab) (fuel center of gravity and the of the front axle. tanks full) [pounds]. Including option weight. = Passenger load (See E-Series Passenger Load = Vehicle wheelbase [inches].
  • Page 17 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...
  • Page 18 TABLE C TABLE F = Vertical distance from ground to chassis CG = Horizontal distance from front axle to cargo CG: (Dimensions are inches) Model WB (in) CGhl (in)† E-150 & E-250 Van <8000 lb GVWR = 28.5 Regular Van E-250/350 SRW Van or Wagon >8000 lb GVWR = 32.0 †Extended Van or Extended Wagon...
  • Page 19 18 and 19, the statements immediately below, source as provided by Ford Motor Company. See the concerning Standard 108 Lamps, Reflective Devices, figure below for circuit location.

  • Page 20: Headlamps (Canada Only)

    Additionally, if the completed vehicle overall length is 9.14 meters [30 feet] or more, intermediate side marker lamps and reflex reflectors (not supplied by Ford Motor Company) are also required for compliance with Standard 108. Item...

  • Page 21: 111 Rearview Mirrors

    • E-Series Basic (Stripped) Chassis: 111, Rearview Mirrors, if: Conformity with Standard 108, Lamps, Reflective • The mirrors and their mounts as supplied by Ford Devices, and Associated Equipment, is not substantially Motor Company, are not removed, relocated, replaced, affected by the design of this incomplete vehicle;...

  • Page 22: 118 Power Operated Window, Partition, And Roof

    111, Rearview Mirrors, if: introduced into the hydraulic brake system. • The mirrors and their mounts as supplied by Ford 118 The statement below is applicable to all incomplete Motor Company are not removed, relocated, replaced, vehicle types not equipped with power windows when or altered.

  • Page 23: 124 Accelerator Control Systems X X X Xx

    – Brake system reservoir labeling – Suspension ride height or spring rate – Wheelbase • Any removal of a Ford body or chassis component is accompanied by the addition of equal weight. • The maximum GAWRs and GVWR, as identified on...

  • Page 24: 201 Occupant Protection In Interior Impact X(2)

    If a vehicle is equipped with a Passenger Side Air Bag appropriate range determined from Table E. 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.

  • Page 25: 202 Head Restraints X(2) X(2) X(2) X(2)

    204 INFORMATION seat assemblies and their anchorages, the floor pan, or floor pan reinforcements. Refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Second Unit Body • The added seat trim, on vehicles equipped with...

  • Page 26: 206 Door Locks And Door Retention Components X Xx

    Incomplete E-Series Van and Cutaway vehicles with no made and if additional glazing materials installed by front seats provided by Ford Motor Company, refer to the a subsequent stage manufacturer conforms to the Design Recommendation section of the Ford Truck Body requirements of Standard 205.

  • Page 27: 207 Seating System

    Ford completed vehicles. If these anchorages Figure B for E-Series on page 31. are used without the appropriate Ford seats, seat belt Any seating systems added to this vehicle must conform systems, and hardware, Ford Motor Company makes no to the applicable requirements of this Standard.

  • Page 28: 208 Occupant Crash Protection X(5)(6) X(5)(6) X(5)(6) X(5)(6) X(5)(6)

    – Center roof mounted consoles may extend down front seats option if the GVWR is 3856 kg [8,500 lb] no more than 3 inches as measured from the Ford or less and the Unloaded Vehicle Weight, when installed headliner† and width is limited to 8 inches completed, is 2495 kg [5,500 lb] or less: (4 inches either side of the vehicle centerline).
  • Page 29 – Center roof mounted consoles may extend down specified in Figure C on page 32. no more than 3 inches as measured from the Ford • Window or roof modifications do not exceed the installed headliner† and width is limited to 8 inches defined cut out areas shown in the Figures G1, G2 (4 inches either side of the vehicle centerline).
  • Page 30 – Center roof mounted consoles may extend down relocated, modified, or altered in any way as shown no more than 3 inches as measured from the Ford in Figure E on page 33. installed headliner† and width is limited to 8 inches •...
  • Page 31 • The Air Bag Supplemental Restraint System as 208 The statement below is applicable to the following vehicle type: installed by Ford Motor Company (see Figure E on page 33) is not removed, relocated, modified or altered • E-Series Basic (Stripped) Chassis in any way.
  • Page 32 3C24-15602B82 FRONT OF ADJ. ASY. F65B-15602B90 BOLT TORQUE VEHICLE F65B-602B90 COVER ASY. 47.5 ± 7.2 Nm 3C24-15602B82 COVER ASY. [35 ± 5 ft-lb] ADJ. ASY. PANEL ASY. UPPER CUTAWAY & VAN MODELS 3C24-1560262 3C24-1560262 COVER ASY. COVER ASY. FRONT OF 1 REQ’D.
  • Page 33 SEAT ASY. SEAT ASY. PIA BOLT TORQUE 35.0 6.0 Nm [29.5 4 ft-lb] N801078-S58 SCREW M8x1.25 HEX 4 REQ’D. TORQUE 25.0 3.8 Nm N801078-S424 [18.4 2.8 ft-lb] SCREW M8 x 1.25 HEX 4 REQ’D. 4C24-15618B47-AA TORQUE 25.0 3.8 Nm TRACK ASY. [18.4 + 2.8 ft-lb] XC2A-1561202-A 2C24-1561701-A...
  • Page 34 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) 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]...
  • Page 35 RESTRAINT CONTROL MODULE UNDER DRIVER'S SEAT �������� ���������� ����� ����� ������� ������ ������ ��������� ������ ��������� ��������� ���������� �������������� ���������������� ������������ ��������� ��������� ���� ����� ������ ����� ����������� ������ ������� ���������������������������������������������� ������������������������������������������������ DO NOT RELOCATE. MUST BE METAL-TO-METAL ����������������������������������������� CONTACT FIGURE E1 –...
  • Page 36 CUT LINE CUT LINE CUT LINE SECTION CC SECTION BB CUT LINE CUT LINE SECTION AA SECTION DD 711.2 711.2 [ 28.00 ] [ 28.00 ] MAXIMUM MAXIMUM THE SPOTWELDS (X) IN THIS AREA MUST REMAIN INTACT. FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS.
  • Page 37 CUTLINE SECTION FF CUTLINE CUTLINE SECTION GG SECTION EE THE SPOTWELDS ( X ) IN THIS AREA MUST REMAIN INTACT. 533.4 [21.00] MAXIMUM WITH SLIDING DOOR 711.2 [28.00] MAXIMUM WITH CARGO DOORS FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW [ ] DIMENSIONS ARE IN INCHES FOR THE PURPOSE OF CLARITY.
  • Page 38 REGULAR VAN EXTENDED VAN OR WAGON 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. FRONT OF...

  • Page 39: 209 Seat Belt Assemblies X X Xx

    Ford completed vehicles. If these anchorages strap, marking, installation instructions, usage and are used without the appropriate Ford seats, seat belt maintenance instructions, workmanship, webbing systems, and hardware, Ford Motor Company makes no performance, hardware performance, and assembly representation as to conformity with this Standard.

  • Page 40: 210.1, User-Ready Tether Anchorages For Restraint

    † 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.
  • Page 41 • Incomplete E-Series Van or Wagon the window glazing materials, window mounting system, or the surrounding door structure as provided by Ford This vehicle, when completed, will conform to Standard Motor Company. 214, Side Impact Protection, if: 217 Canadian Requirements: •...
  • Page 42 • No alterations are made to the front passenger seat tether anchorages and access to the anchorages is The Cutaway body structure as manufactured by Ford, not restricted, and no alterations are made to the seat does not meet the strength requirements of FMVSS 220, assemblies, their anchorages, the floor pan, or floor School Bus Rollover Protection;...
  • Page 43 301, Fuel System Integrity, if: 301 INFORMATION • The following fuel system components, as installed by Ford Motor Company, are not to be removed, The Unloaded Vehicle Weight of the completed relocated, altered, or modified in any way: vehicle may significantly affect its capability to meet the requirements of FMVSS 301.
  • Page 44 † 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.
  • Page 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.
  • Page 46 • The body installed by a subsequent stage manufacturer • The E-Series Basic (Stripped) Chassis aft-of-axle fuel and the Ford installed fuel system components are filler cap, pipe, hose(s), and attaching hardware are located and mounted as follows: installed as shown in Figure I, below. All components must be securely retained to remain intact when the –...
  • Page 47 † 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.
  • Page 48 Items 8 or 9 to Items 10 or 11 3 on vertical side of item 10 or 11, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers Item 16 50.8mm [2.00] Centers 25.4 FORD PROVIDED 1318.3 [1.00] 12.0mm BOLT (6 REQ’D) TYPICAL [ 51.90]...

  • Page 49: Statements Of Conformity

    BOTH ENDS OF ITEMS #5, 6, AND 7 CROSS SILLS MUST BE WELDED COMPLETELY TO ITEM #10 LEFTSIDE AND ITEM #11 RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDS THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN COMPLETED. 36.1 [ 1.42 ] 71.6 [ 3.13 ] 851.6...

  • Page 50: Canadian Vehicles

    • The Powertrain Control Module (PCM) must not be relocated in Canada or for sale or use in Canada are subject to from the position as installed by Ford Motor Company. 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”.

  • Page 51: Emission Certification Information

    CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS Ford are not exceeded. If these restrictions are exceeded, OF THE UNITED STATES. FOR EXAMPLE, VEHICLES or if the vehicle is modified such that it will not comply with...

  • Page 52: Exterior Noise

    Motor Company comply with these requirements. If the subsequent stage manufacturer adds to or modifies the However, the Basic (Stripped) Chassis as built by Ford is too fuel system in any manner, it becomes the responsibility incomplete to constitute a regulated vehicle and Ford does of the modifier to assure compliance with the applicable not represent that it complies with those regulations.

  • Page 53: California Fuel Vapor Recovery

    Z). The cylindrical zone uses the axis RADIO FREQUENCY INTERFERENCE (RFI) described above, starts at the outer most surface of the Ford supplied fuel filler housing, and projects outward (away from The ignition system on your vehicle (if other than a Basic the frame).

  • Page 54: Supplements

    SUPPLEMENTS E-SERIES (May, 2004)

  • Page 55: 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 chassis cab and incomplete vehicles.
  • Page 56 FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN, MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE, ONTARIO L6J 5E4...

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