Ford - E 150 - Workshop Manual - 2012 - 2012

DO NOT DESTROY: THIS MANUAL IS REQUIRED BY LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER. 2012 E-SERIES INCOMPLETE VEHICLE MANUAL Incomplete Vehicle Types For This Manual INCOMPLETE E-SERIES VANS & WAGONS E-SERIES CUTAWAY E-SERIES BASIC CHASSIS February, 2011 CC24-19A268-AA U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS (Application By Vehicle Type) Vehicle Type Bus (Not Truck Truck Standard School School (Not (Walk-in Number Title of Standard Bus) Bus Walk-In Van) MPV Van) 101 Control Location, Identification 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 108 Lamps, Reflective Devices & Associated Equipment X X X X X 108.1 Headlamps (Canada only) X X X X X 110 Tire Selection and Rims (U.S. only) X(2) X(2) X(2) X(2) X(2) 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 Identification Number (Canada only) X X X X X 116 Motor Vehicle Brake Fluids X X X X X 118 Power Operated Window, Partition, and Roof Panel Systems X(2) X(2) X(2) 119 (8) New Pneumatic Tires for Motor Vehicles 120 Tire Selection and Rims for Motor Vehicles X(9) X(9) X(9) X(9) X(9) 124 Accelerator Control Systems X X X X X 126 Electronic Stability Control Systems X(2) X(2) X(2) X(2) X(2) 131 School Bus Pedestrian Safety Devices (except Multifunction School Activity Bus) X 138 Tire Pressure Monitoring Systems X(2) X(2) X(2) X(2) X(2) 139 New Pneumatic Radial Tires for Light Vehicles 201 Occupant Protection in Interior Impact X(2)(7) X(2)(7) X(2) X(2) X(2)(7) 202a 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 206 Door Locks and Door Retention Components X X X 207 Seating System X X X X X 208 Occupant Crash Protection X(4) X(4) X(4) X(4) X(4) 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(6) X(6) X(6) X(6) 210.2 Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions (Canada only) X(6) X(6) X(6) X(6) 212 Windshield Mounting X(2) X(2) X(2) X(2) 213 Child Restraint Systems (U.S. only) X X X X X 213.4 Built-In Child Restraint System & Built-In Booster Cushions (Canada only) X X X X X 214 Side Impact Protection X(2)(5) X(2)(5) X(2)(5) X(2)(5) 217 Bus Window Retention and Release X X 219 Windshield Zone Intrusion X(2) X(2) X(2) X(2) Equipment (1) X X X X(2) X X(9) X(9) X(2) X(2) X(2) X X X X (Continued on Page 1) U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS E-SERIES (February, 2011) U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS (Application By Vehicle Type) (Continued from Inside Front Cover) Vehicle Type Standard Number 220 221 222 225 301 301.1 301.2 302 303 304 403 404 PART 393.67 PART 565 1106 Bus (Not School School Title of Standard Bus) Bus School Bus Rollover Protection X School Bus Body Joint Strength X School Bus Passenger Seating and Crash Protection X Child Restraint Anchorage Systems (U.S. only) X(6) X(6) Fuel System Integrity X(2) X LPG Fuel System Integrity (Canada only) CNG Fuel System Integrity (Canada only) Flammability of Interior Materials X X Fuel System Integrity of Compressed Natural Gas Vehicles (U.S. only) X(2) X(2) Compressed Natural Gas Fuel Container Integrity (U.S. only) X X Platform Lift Systems for Motor Vehicles Platform Lift Installations in Motor Vehicles X X Parts and Accessories Necessary for Safe Operation – Liquid Fuel Tanks Vehicle Identification Number (VIN) Requirements X X (U.S. only) Noise Emissions (Canada only) X X (1) This column identifies Standards that have equipment/component requirements. (2) Applicable to vehicles with a gross vehicle weight rating (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) Injury criteria are applicable to vehicles with a GVWR of 3856 kg [8500 lb] or less and an unloaded vehicle weight (UVW) 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. E-SERIES (February, 2011) Truck (Not Walk-In Van) Truck (Walk-in Van) MPV X(6) X(2) X X X X(6) X(2) X X X X(6) X(2) X(2) X(2) X(2) X X X X X X X X X X X X X Equipment (1) X X X (5) Dynamic Performance Requirements apply to MPVs, trucks and buses with a GVWR of 2722 kg [6000 lb] or less. (6) Applicable to vehicles with GVWR of 3856 kg [8500 lb] or less (and Canada only: UVW of 2495 kg [5500 lb] or less), and to buses, including school bus, with a GVWR of 4536 kg [10,000 lb] or less. (7) The requirements of section S6 of Standard Number 201 (United States) do not apply to buses with a GVWR greater than 3860 kg [8510 lb] and walk-in van type trucks. (8) Canadian 119 requirements are found in the Motor Vehicle Tire Safety Standards. (9) Applicable to vehicles with a GVWR greater than 4536 kg [10,000 lb] (U.S. only). 1 U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS 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 final 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 Traffic 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 identified in the “Statements of Conformity” and the “Canadian Vehicles” sections of this manual. The “Emission Certification 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 in the “Emissions Certification Information” section of this manual under the headings “Unleaded Gasoline Label,” “Warranty and Maintenance,” and “Emission Control Information Label”). It is the responsibility of the final 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 specific statements are intended to aid subsequent stage manufacturers in avoiding instances of inadvertent noncompliance to particular standards. Note that the final responsibility for the compliance of the completed vehicle rests with the final stage manufacturer who is required by law to certify, as prescribed by Title 49, Code of Federal Regulations, Part 567.5, 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 modifications for any particular application other than expressly stated herein. Intermediate and final stage manufacturers must exercise proper engineering judgment to determine if a modification is appropriate for their specific 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 affixed to a vehicle. INTRODUCTION 2 E-SERIES (February, 2011) TABLE OF CONTENTS U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS ........................................................ Inside Cover INTRODUCTION .................................................................................... 2 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 High Altitude Requirements...............................................................49 Emission Control Hardware...............................................................49 Unleaded Gasoline Label................................................................. 45 Exterior Noise................................................................................... 49 Tampering with Noise Controls..........................................................50 Warranty and Maintenance............................................................... 50 Evaporative Emissions...................................................................... 50 Malfunction Indicator Light (MIL)...................................................... 50 Ozone Depleting Substance (ODS)...................................................50 Vehicle 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 ....................................Inside Back Cover E-SERIES (February, 2011) 3 TABLE OF CONTENTS DEFINITIONS The following definitions are from Title 49, Code of Federal Regulations (49CFR), Parts 567.3, 568.3 and 571.3 where noted. Canadian definitions are from Canadian Motor Vehicle Safety Regulations (CMVSR), 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. 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 configuration 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 defined in section 100 of Schedule IV, where the overall seat configuration 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 [company that (CMVSR)] performs such manufacturing operations on an incomplete vehicle that it becomes a completed vehicle. (49CFR567.3) Gross Axle Weight Rating (GAWR) – the value specified 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 specified by the manufacturer as the loaded weight of a combination vehicle. (49CFR571.3) Gross Vehicle Weight Rating (GVWR) – the value specified 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 Defining and Measuring Vehicle Seating Accommodation. (point H) Incomplete Vehicle – an assemblage consisting, at a minimum, of chassis (including the frame) structure, power train, steering system, suspension system, and braking system, in the state that those systems are to be part of the completed vehicle, but requires further manufacturing operations to become a completed vehicle. (49CFR567.3) 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 Specification KKK-A-1822-F). Ford Motor Company also includes within its definition 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. (Ford Motor Company) 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 occupant compartment and cargo-carrying, work performing, or load-bearing components to perform its intended function. (Ford Motor Company) Bus – a motor vehicle with motive power, except a trailer, designed for carrying 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. (49CFR567.3) 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) DEFINITIONS 4 E-SERIES (February, 2011) 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 part of the completed vehicle, but requires further manufacturing operations to become a completed vehicle or (b) that is an incomplete trailer. (véhicule incomplet) Incomplete Vehicle Manufacturer – a person [company that (CMVSR)] who manufactures an incomplete vehicle by assembling components none of which, taken separately, constitute an incomplete vehicle. (49CFR567.3) Intermediate Manufacturer – a person [company (CMVSR)], other than the incomplete vehicle manufacturer or the final stage manufacturer, who [that (CMVSR)] performs manufacturing operations on a vehicle manufactured in two or more stages. (49CFR567.3) 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; self-contained toilet; heating and/or air conditioning [system that can function independently of the vehicle engine (CMVSR)]; 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 three-wheeled vehicle, 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 defined in SAE J1100 (June 1984), which: (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; (c) Simulates the position of the pivot center of the human torso and thigh; and (d) Is the reference point employed to position the twodimensional drafting template described in SAE J826 (May 1987). (abbreviated by Ford Motor Company) E-SERIES (February, 2011) Seating Reference Point (Canada) – the unique Design Hpoint, as defined 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, (c) simulates the position of the pivot centre of the human 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 final 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 final 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 primarily 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 fluids 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 fluids necessary for the operation of the vehicle filled 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 final 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 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. 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) 5 DEFINITIONS GENERAL INFORMATION Information in this section is provided pursuant to Title 49, Code of Federal Regulations, Part 568 – “Vehicles Manufactured in Two or More Stages”, and Section 6 of the Canadian Motor Vehicle Safety Regulations (CMVSR) – “Vehicles Manufactured in Stages.” Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards and affix a label to each incomplete vehicle that is completed in accordance with 49CFR567.5. Section 6.6 of the CMVSR provides labeling requirements for vehicles that are to be sold in Canada. DIRECTIONS STATEMENTS OF CONFORMITY IMPORTANT: The “Statements of Conformity” section 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 affixed to the cover of this manual. These statements, in most cases, apply to specific types of incomplete or completed vehicles and identify GVWR and UVW weight ranges. 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 affixed to the cover of this manual, and must not exceed the specified GVWR, GAWRs, or the Unloaded Vehicle Weight limits when specified in this manual. This vehicle was certified with a GVWR over 3856 kg [8500 lb]. If the GVWR is modified to less than 3856 kg [8500 lb], additional Federal and/or Canadian Motor Vehicle Safety Standards (F/CMVSS) may apply. The incomplete vehicle type is identified 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 affixed to the cover of this document. The Completed Vehicle Types charts on page 8 identifies how various incomplete vehicles with an Optional Prep Packages or a Trim Code, may be completed. VEHICLE SPECIAL ORDER (VSO) VEHICLES VSO vehicles can be identified by a six digit number with the letters VSO below the digits in the lower right corner of the Incomplete Vehicle Information Label which is affixed to the driver-door lock pillar. See the sample label on page 7. Each statement of conformity is identified 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. The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles. These vehicles are identified 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. Compliance statements provided in this manual are of the three following types (49CFR568.4): Type I • A statement that the vehicle, when completed, will conform to the standard if no alterations are made in identified components of the incomplete vehicle. FORD TRUCK ASSISTANCE 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 incomplete vehicles. The Ford Truck Body Builders Layout Book may be accessed via the web at www.fleet.ford.com/truckbbas under the “Publications” tab. Type II • A statement of specific conditions of final manufacture under which the incomplete vehicle manufacturer specifies that the completed vehicle will conform to the standard. Type III • A statement that conformity with the standard cannot be determined based upon the components supplied on the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard. GENERAL INFORMATION The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. • Call (877) 840-4338 • E-mail via the web at www.fleet.ford.com/truckbbas under the “Contact Us” tab 6 E-SERIES (February, 2011) VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER California Air Resources Board (CARB), requires a Vehicle Identification Number (VIN) Label having a non-contact, barcode, reading wand capability. The bar-code directly below the VIN on the Incomplete Vehicle Information Label, when provided, will comply with this regulation. The cover of this manual identifies the three incomplete vehicle configurations for which compliance representations are contained in this manual. Also, a label is affixed to the cover which includes the Vehicle Identification Number (VIN) for the specific vehicle to which this manual belongs. The label identifies the following information which pertains only to the vehicle with the corresponding VIN. • The GVWR The Canadian Motor Vehicle Safety Act and Regulations require installation of an Incomplete Vehicle Information Label with the National Safety mark on it on vehicles manufactured for sale in Canada. A sample of a typical label is shown below. • The front and rear GAWRs OPTIONAL PREP PACKAGES • Tire and wheel size Incomplete vehicles produced by Ford Motor Company, in some instances, are equipped with an optional prep package. These include the Ambulance Prep, School Bus Prep, Motorhome Prep, and Shuttle Bus Prep. The completed vehicle type charts on page 8 will identify incomplete vehicles and the optional prep packages or trim codes that may be required by Ford Motor Company if final stage manufacturers wish to rely on the Statements of Conformity or, in some cases, preserve the Ford Motor Company new vehicle warranty. • Cold tire inflation pressure (kPa/PSI) • Completed vehicle type(s) into which the incomplete vehicle may be manufactured • Optional prep package when the vehicle is so equipped INCOMPLETE VEHICLE INFORMATION LABEL All E-Series incomplete vehicles manufactured by Ford Motor Company will have an Incomplete Vehicle Information Label affixed to the driver-door lock pillar, except Basic (Stripped) Chassis. The Incomplete Vehicle Information Label for the Basic (Stripped) Chassis is affixed to the front structure and a second label is provided to be permanently affixed in an acceptable location per 49CFR567.4. A sample of a typical label is shown below. If an incomplete vehicle is equipped with an optional prep package, both the Incomplete Vehicle Information Label affixed to the vehicle and the label on the front of this manual will identify the prep package. The 5th, 6th, and 7th digits of the Vehicle Identification Number (VIN) will identify the incomplete vehicle type. These three digits are used in the Completed Vehicle Types charts on page 8. DATE OF MANUFACTURE BAR CODE V.I.N . (CALIFORNIA) VEHICLE TYPE (SEE CHART ON PAGE 8) EQUIPPED WITH THE FORD AMBULANCE PREP PKG. 410047 VSO OPTIONAL PREP PACKAGE VSO VEHICLE TYPICAL E-SERIES – U.S. DATE OF MANUFACTURE VEHICLE TYPE (SEE CHART ON PAGE 8) 1019 VSO VSO VEHICLE TYPICAL E-SERIES – CANADA INCOMPLETE VEHICLE INFORMATION LABELS E-SERIES (February, 2011) 7 VEHICLE DESCRIPTION COMPLETED VEHICLE TYPES E-Series E1B E1E E2E E2F E3B E3E E3F E3K E4F E4K S1E S2E S3B S3E S3H Incomplete E-150 Wagon X 6 Incomplete E-150 Regular Van X 5 Incomplete E-250 Regular Van X 5 E-250 Super Duty Cutaway (mid-ship fuel tank) X Incomplete E-350 Super Duty Wagon X 6 Incomplete E-350 Super Duty Regular Van X 5 1 E-350 Super Duty Cutaway (aft-of-axle fuel tank) X 3 1 E-350 Super Duty Basic (Stripped) Chassis X E-450 Super Duty Cutaway X 3 1 E-450 Super Duty Basic (Stripped) Chassis X Incomplete E-150 Extended Van X 5 Incomplete E-250 Extended Van X 5 Incomplete E-350 Super Duty Extended Wagon X 6 Incomplete E-350 Super Duty Extended Van X 5 1 E-350 Super Duty Cutaway (mid-ship fuel tank) X (1) (2) (3) (4) (5) (6) 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. COMPLETED VEHICLE TYPES 8 SCHOOL BUS BUS (NOT SCHOOL BUS) MPV (AMBULANCE) TRUCK INCOMPLETE VEHICLES MPV 5TH, 6TH, 7TH VIN DIGIT TRUCK (WALK-IN VAN) COMPLETED VEHICLES 6 4 2 4 2 6 5 Ambulance Prep Package School Bus Prep Package Motorhome Prep Package Shuttle Bus Prep Package Recreational Van Center Aisle Seat Prep Package E-SERIES (February, 2011) 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, 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. 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 Identification Number, if the vehicle identification number mounted on the top of the instrument panel is not removed, altered, or modified 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. 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 definition 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 27, for E-Series type vehicles. • The controls, 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 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 identifications. Any controls, displays, and 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, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. 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 Identification Number, if: • The E-Series vehicle identification number printed on the label affixed 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 modified. • 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 identifications. • The driver-seat is not replaced, relocated, or modified 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. E-SERIES (February, 2011) 9 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, Starter Interlock, and Transmission Braking 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. STATEMENTS OF CONFORMITY 102 10 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 Lever Sequence, Starter Interlock, and Transmission Braking 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, brake-shift interlock system, the starter interlock system, and wiring circuit (except as noted below) 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 removed prior to completion of the vehicle. • After installing, securing, and connecting the Smart Power Distribution Junction Box (SPDJB), a short jumper with a Removal tag that is connected to the steering column must be removed. This jumper allows brake shift interlock function until after the installation of the SPDJB. The exposed harness connection is to then be mated to the brake shift interlock solenoid on the steering column, and the function is to be verified in all ignition states. If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard. E-SERIES (February, 2011) 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, cannot be determined based upon the components supplied on 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 fluid flow from the washer nozzles to the windshield. 104 105 105 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, modifications, 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; label is not to be obstructed by additional underhood components – 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-350/450 minimum Unloaded Vehicle Weight (UVW – see definition on page 5) must be at least the weights shown on the following table: MINIMUM UNLOADED VEHICLE WEIGHT (UVW) WHEN CUTAWAY COMPLETED AS A SCHOOL BUS Vehicle 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, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. Weight Kilogram [Pound] E-350 SRW (1) E-350 DRW E-450 DRW 2540 [5600] 3030 [6680] 3821 [8425] SRW – Single Rear Wheels DRW – Dual Rear Wheels (1) Aft-of-axle fuel tank • The maximum GAWRs and GVWR, as identified 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 defined in the following table: 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 specific vehicle for required information. Abbreviation definitions and a vehicle diagram to assist with the equations for the Standard 105 segment are shown on page 13. 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. CENTER OF GRAVITY FOR E-SERIES CUTAWAY COMPLETED AS A SCHOOL BUS E-350 E-350 SRW DRW mm [in] mm [in] Vertical Maximum (1) 302.0 [11.9] Horizontal Maximum (2) 2159.0 [85.0] Horizontal Minimum (2) 1651.0 [65.0] Location E-450 DRW mm [in] 2718.0 [107.0] (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. E-SERIES (February, 2011) 11 STATEMENTS OF CONFORMITY 105 The statements below are applicable to the following incomplete vehicle types except when completed as a school bus: • 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, modifications, 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 Hydroboost – Engine belt drive system – Wheelbase • No additional sound deadener or rust proofing material, that may be applied to the vehicle, can interfere with proper parking brake cable function. • No part of add on equipment, i.e. toolboxes, flat bed attaching brackets, etc., can interfere with the movement of parking brake cables or air flow 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 14. • The maximum GAWRs and GVWR, as identified 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 service or parking brake 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 STATEMENTS OF CONFORMITY 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 A) 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 15. 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 of 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 CGv = ( CGvbWb + CGvc Wc + Wl ) + 25P GVWR EQUATION B P x CG         + Wrl) x WB Wrb + Wrc +( ( WB ) = hp CGh GVWR E-SERIES PASSENGER LOAD GVWR [lb]   8520 – 10,000 10,001 – 19,000 12 P [lb] 400 500 E-SERIES (February, 2011) FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES P = Passenger load (See E-Series Passenger Load Table page 12). WB = Vehicle wheelbase [inches]. CGv = Vertical distance from the ground to the center of gravity [inches] of the completed vehicle. Wt = Total unladen weight = (Wb + Wc + P) CGh = Horizontal distance from of the front wheels to completed vehicle center of gravity [inches]. GVWR = Gross Vehicle Weight Rating of the vehicle [pounds]. WI CGvb = Vertical distance from the ground to the center of gravity of the SUB and/or permanently attached added equipment [inches]. Wrl 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 15). CGhp = Horizontal distance from the of the front wheels to the P [inches] (passenger load) (taken from Table D, page 15). Wb = Weight of the SUB and/or permanently attached added equipment [pounds]. Wrb = Weight at the rear wheels of the SUB 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. Wc = Weight of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight. = Remaining cargo capacity [pounds]. Where: Wl = GVWR - (Wb + Wc + P) = Weight of the remaining cargo capacity on the rear wheels [pounds]. WrI = (CGhI)WI WB CG hI = Horizontal distance from the of the front wheels to the cargo center of gravity [inches] (taken from Table C page 15). 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 Body 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. WB CG hl CG h CG OF CHASSIS CG OF COMPLETED VEHICLE CG hp CG OF SUB SUB P CG vb CG v CG vc Wc Wt GVWR W rl E-SERIES (February, 2011) 13 W rb Wb W rc Wl STATEMENTS OF CONFORMITY TABLE A MAXIMUM UNLOADED VEHICLE WEIGHT (UVW) FOR INCOMPLETE VEHICLES WHEN COMPLETED (1) (This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR) Model E-150 Regular Van E-150 Regular Wagon E-250 Regular and Extended Van E-250 Cutaway (2) E-350 Regular and Extended Van E-350 Regular and Extended Wagon E-350 Cutaway SRW (mid-ship fuel tank) (3) E-350 Cutaway SRW (aft-of-axle fuel tank) E-350 Cutaway DRW E-350 Basic (Stripped) Chassis SRW E-350 Basic (Stripped) Chassis DRW E-350 Basic (Stripped) Chassis SRW E-350 Basic (Stripped) Chassis DRW E-350 Basic (Stripped) Chassis DRW Wheelbase Millimeter [inch] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 3505 [138] 4013 [158] 4013 [158] 4470 [176] Maximum Unloaded Vehicle Weights – Kilogram [pound] 3130 [6900] 3130 [6900] 3130 [6900] 2698 [5949] 3583 [7900] 3583 [7900] 3021 [6660] 3856 [8500] 3856 [8500] 3946 [8700] 3946 [8700] 3946 [8700] 3946 [8700] 3946 [8700] (1) Maximum unloaded vehicle weight values shown in this table are limits for purposes of F/CMVSS conformity only. See Emission Certification information on page 45 for possible additional weight restrictions to meet emission requirements. (2) Frontal area limited to 54.5 ft2 on VECI label (3) Frontal area limited to 60.0 ft2 on VECI label TABLE B MINIMUM SUB WEIGHT Model E-250 Cutaway SRW 3505mm [138 in] WB E-350 Cutaway SRW 3505mm [138 in] WB E-350 Cutaway DRW 3505mm [138 in] WB E-350 Cutaway DRW 4013mm [158 in] WB E-350 Cutaway DRW 4470mm [176 in] WB E-450 Cutaway DRW 4013mm [158 in] WB E-450 Cutaway DRW 4470mm [176 in] WB E-350 Basic (Stripped) Chassis DRW All WB E-450 Basic (Stripped) Chassis DRW All WB Kilogram [Pound] 438 [965] 381 [840] 204 [450] 238 [525] 238 [525] 238 [525] 238 [525] 862 [1900] 998 [2200] Minimum unloaded vehicle weight for Cutaways completed as school buses is defined in Standard 105 requirements. STATEMENTS OF CONFORMITY 14 E-SERIES (February, 2011) TABLE C TABLE F CGhl = Horizontal distance from front axle to cargo CG CGVC = Vertical distance from ground to chassis CG Model Regular Van †Extended Van or Extended Wagon †Cutaway (SRW) (DRW) †Comm. Cab/Box Partition (DRW) †RV (DRW) †Comm. No Partition (DRW) †RV (DRW) †Comm. (DRW) WB (in) 138 138 138 138 158 158 158 176 176 Model CGhl (in)† 116 126 121 127 134 138 143 153 160 CGVC (in) E-150/250/350 SRW Van or Wagon E-250/350 Cutaway E-450 Cutaway E-350/450 Basic (Stripped) Chassis 32.0 28.0 26.5 26.5 † 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 E CGV = Vertical distance from the ground to the completed vehicle center of gravity Requires Use of 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. Model E-150/250 E-350 (SRW) <9600 Ib GVWR E-SERIES (February, 2011) WB (in) 138 138 158 Equation for CGV Range Upper Limit (in) Lower Limit (in) CGV = 1.27 x CGh - 59.0 1.27 x CGh - 77.5 CGV = 1.27 x CGh - 60.0 1.27 x CGh - 80.0 CGV = 1.27 x CGh - 69.5 1.27 x CGh - 90.7 15 STATEMENTS OF CONFORMITY 106 The statement below is applicable to all incomplete 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 modified and if no brake hose assemblies are added. 108 In addition to the statements pertaining to particular incomplete vehicle types which follow on pages 17 and 18, the statements immediately below, concerning Standard 108 Lamps, Reflective Devices, and Associated Equipment are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: No additional components 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. Conformity with Standard 108, S.12, Headlamp Concealment Devices, cannot be determined based upon the components supplied on 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, Lamps, Reflective Devices, and Associated Equipment if a Center High Mounted Stop 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 figure below for circuit location. 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. CHMSL CONNECTOR FRONT OF VEHICLE E-SERIES CUTAWAY CENTER HIGH-MOUNTED STOP LAMP (CHMSL) ELECTRICAL CONNECTOR LOCATION STATEMENTS OF CONFORMITY 16 E-SERIES (February, 2011) TABLE G Standard 108 Lighting Equipment 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 lighting equipment as indicated in Table G on this page (identified 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 reflex reflectors (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 (identified by the code S in Table G, on this page) are designed and installed to conform to all the applicable requirements of Standard 108. The completed vehicle, with these components installed, will conform to Standard 108 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 configuration as to impair the visibility and conformity to the photometric requirements of the installed lamps and reflective devices. Specific requirements for lighting and associated equipment are listed by incomplete vehicle type in Table G on this page. Lamps, reflective 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. All electrical equipment added to the vehicle 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. 108 The statements below are applicable to the following incomplete vehicle types: • Incomplete E-Series Van or Wagon This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices, and Associated Equipment, if the subsequent stage manufacturer does not: • Remove, alter, 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 reflective devices 108 (Continued Next Page) Width 2032 mm [80 in] or more Item Headlamps Tail Lamps Stop Lamps Center High Mounted Stop Lamp (CHMSL) License Plate Lamps Reflex Reflectors – Side Front – Side Rear – Rear Side Marker Lamps – Front – Rear Back-Up Lamps Turn Signal Lamps – Front – Rear Turn Signal Operating Unit Turn Signal Flasher (2) Vehicular Hazard Warning Signal Operating Unit Vehicular Hazard Warning Signal Flasher Identification Lamps – Front – Rear Clearance Lamps – Front – Rear Parking Lamps School Bus Lamps and Switches (School Bus except Multifunction School Activity Bus) Width less than 2032 mm [80 in] E-Series Completed as Truck, MPV, Bus or School Bus S R/D R/D S R/D R/D R R/D S R R S R R/D S R/D S S N R/D S R R S R R/D S R/D S S S S S N N N N R R S R R R(1) R N R S Required on completed vehicle 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) Cab-mounted clearance lamps, if supplied, may not adequately indicate overall width of the vehicle per F/CMVSS 108; additional clearance lamps may be required on the Second Unit Body if the SUB is higher than the cab. (2) Turn signal flasher function is contained within the Smart Power Distribution Junction Box features. All chassis cab and stripped chassis vehicles are configured to provide the function of a variable-load turn signal flasher. E-SERIES (February, 2011) 17 STATEMENTS OF CONFORMITY 108 (Continued) 108 The statements below are applicable to the following incomplete vehicle type: • E-Series Basic (Stripped) Chassis: Conformity with Standard 108, Lamps, Reflective Devices, and Associated Equipment, cannot be determined based upon the components supplied on 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 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: The preceding statements for Standard 108 are appropriate compliance representations for CMVSS 108, Lighting, 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 modified. 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 final stage manufacturer must affix a tire placard as specified in paragraph S4.3 of FMVSS 110. The decal must be affixed 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 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 27 corresponding to the particular incomplete vehicle type. • Any modifications 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 field of view through the inside mirror, Standard 111 may require that the vehicle have a flat 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, cannot be determined based upon the components supplied on 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, cannot be determined based upon the components supplied on 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. TIRE AND LOAD INFORMATION SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION The combined weight of occupants and cargo should never exceed XXX kg or SEATING CAPACITY TOTAL : 5 ORIGINAL TIRE SIZE FRONT REAR 111 P195 / 70R14 P195 / 70R14 FRONT: 2 REAR: 3 COLD TIRE INFLATION PRESSURE FRONT REAR 200KPA, 29PSI 200KPA, 29PSI COMPACT TIRE SIZE COLD TIRE INFLATION PRESSURE T125/70D15 420KPA, 60PSI 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 modifications 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 modified other than for the addition of seat trim. If any alteration blocks the rear field of view through the inside mirror, Standard 111 may require that the vehicle have a flat glass mirror on the passenger side. STATEMENTS OF CONFORMITY 18 E-SERIES (February, 2011) 111 The statements below are applicable to the following incomplete vehicle type when equipped with a flat 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 modifications 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, cannot be determined based upon the components supplied on 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 modified in any way: • Steering column locking mechanism system • Ignition key/transmission shift interlock locking 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 definition, on page 5. 115 Canadian Requirements: The statements for Part 565.4 are appropriate compliance representations for CMVSS 115, Vehicle Identification 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, Motor Vehicle Brake Fluids, so long as any brake fluid added or replaced conforms to the DOT 3 specifications of the standard and contaminants are not introduced into the hydraulic brake system. E-SERIES (February, 2011) 19 118 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: Conformity with Standard 118, Power Operated Window, Partition, and Roof Panel Systems, cannot be determined based upon the components supplied on 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 Information label that is affixed 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 final stage manufacturer must, in accordance with the requirements of Standard 120 and Part 567 of Title 49 Code of Federal Regulations, affix a label to the completed vehicle indicating tire size, rim size, cold inflation pressure, and the gross axle weight ratings. This information is provided on the label that is affixed to the cover of this manual for E-Series vehicles. NOTE: An FMVSS 120 update, effective June 2, 2008, adds Section 10 which includes new Final Stage Manufacturer label requirements for motor homes and recreational vehicles. 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 hardware, adjustable pedal mechanism, or other components of the accelerator control system as installed by Ford Motor Company. • No equipment is added nor existing equipment modified which would restrict operation of the accelerator control system. • No alterations are made to the Pedal Position Sensor and all associated hardware and wiring. See the figure below for component identification. 138 The statement below is applicable to all single rear wheel (SRW) incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less (if equipped): The Tire Pressure Monitoring System is subject to interference from the addition of metallic structures between the wheel-mounted sensor transmitters and the on-board receiver. This vehicle, when completed, will conform to Standard 138, Tire Pressure Monitoring Systems, if: • No alterations are made to the tire pressure sensors (valve stems), wheels, tires, recommended tire pressures, electrical Smart Power Distribution Junction Box, instrument cluster, instrument panel wiring, or software calibrations • Wheelbases are not lengthened • No equipment that emits radio frequency (RF) energy is added to the vehicle • After vehicle upfit, function of the Tire Pressure Monitoring System is verified in accordance with FMVSS 138 139 The statement below is applicable to all incomplete vehicle types: All tires supplied by Ford Motor Company are in full conformity with Standard 139, New Pneumatic Radial Tires for Light Vehicles. If additional tires are installed or the existing tires are replaced by subsequent stage manufacturers, they must conform to the requirements of Standard 139. 201 ELECTRONIC ACCELERATOR CONTROL (Typical) 126 The statement below is applicable to the following incomplete vehicle types: • Incomplete E-series Van or Wagon Vehicles built in two or more stages, or that are altered, are not required to comply with Standard 126, Electronic Stability Control Systems, until September 1, 2012; however, vehicles equipped with a Roll Stability Control (RSC) feature when completed will conform to Standard 126 if: • The vertical center of gravity (CGv) is less than or equal to 39.2" and no modifications have been made to the components of the braking system, suspension system, wheels and tires. Completed vehicle weight should not exceed Maximum Unloaded Vehicle Weights (UVW) as shown in Table A on page 14. For vehicles equipped with RSC, if the vertical center of gravity (CGv) of the vehicle is above 39.2", Ford Motor Company makes no representation as to conformity with this Standard. 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, cannot be deter mined based upon the components supplied on this incomplete vehicle. Accordingly, Ford Motor Company makes no representation as to conformity with this Standard. STATEMENTS OF CONFORMITY 20 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 modified in any way: • Instrument panel • Interior compartment doors • Sun visors • Arm rests Seat backs of front seats installed by Ford Motor Company are designed to meet the 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. 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 specifications for the Seating Reference Point and the torso angle as specified in Figure C page 27. 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. E-SERIES (February, 2011) 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, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. 202a 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 202a, Head Restraints, if: • No alterations are made to the head restraints, the seat assemblies and their anchorages, the floor pan, or floor pan reinforcements. • The added seat trim, 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. 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. (Note: Buses with a GVWR more than 3860 kg [8510 lbs] and the Basic (Stripped) Chassis are exempt from the requirements): • Cutaway • E-Series Basic (Stripped) Chassis • Incomplete E-Series Van (except RV prep package) This incomplete vehicle will conform to Standard 201 Section 6, Occupant Protection in Interior Impact - Upper Interior Head Impact Protection Requirements, if in the process of completing the vehicle none of the following components, as provided by Ford Motor Company, are removed, relocated, altered, or modified either physically or chemically: • A, B, Rear, or other Pillar and Trim • 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 Note: Standard 201 Section 6 requires compliance of all upper interior components located forward of a vertical plane 300 mm behind the seating reference point of the driver’s designated seating position. The Ford Cutaway cab structure terminates 258 mm rearward of the driver’s designated seating reference point (SGRP). Note: If an alterer or final stage manufacturer adds any component located within 300mm rearward of the driver’s designated seating reference point (this includes any of the components listed above, or back panels, bulkheads/ dividers, etc.), these components will have to conform to the requirements of Standard 201 Section 6 where applicable. Also, because the upper interior performance for Cutaway products is affected by the rigidity of the back panel attachment, existing upper interior trim components may require recertification after attachment of a back panel. 202a 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 202a, Head Restraints, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. 201U U.S. Requirements (Section S6 - Upper Interior Components): The statement below is applicable to the following incomplete vehicle type if the GVWR is 4536 kg [10,000 lbs] or less: • Incomplete E-Series Van (RV prep package only) Conformity with Standard 201 Section 6, Occupant Protection in Interior Impact - Upper Interior Head Impact Protection Requirements, cannot be determined based upon the components supplied on the incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. E-SERIES (February, 2011) 21 203 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 modified 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 definition, on page 5. 203 Canadian Requirements: The preceding statements for FMVSS 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. STATEMENTS OF CONFORMITY 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 influence the rearward displacement of the steering column. • The steering column, steering intermediate 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 modified in any way. • No alteration or modifications are made to the body chassis, drivetrain, or front suspension from the B-pillar forward. 204 The statement below is applicable to all incomplete vehicle types, except the Basic (Stripped) Chassis: This vehicle, when completed, will 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, cannot be determined based upon the components supplied on this incomplete vehicle: accordingly, Ford Motor Company makes no representation as to conformity with this Standard. 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, cannot be determined based upon the components supplied on 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. 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 definition, on page 5. 205 206 207 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 floor pan, or floor 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 specifications in Figure B for E-Series on page 26. The Incomplete E-Series Recreational Van or the Incomplete E-Series Wagon 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 (Continued Next Page) TABLE H E-SERIES COMPLETED UNTRIMMED SEAT WEIGHT Description E-Series Captain’s Chair – Manual Tracks E-Series Captain’s Chair – Manual Tracks – Manual Lumbar E-Series Captain’s Chair – Power Tracks – Manual Lumbar STATEMENTS OF CONFORMITY 22 Maximum Weight (lb) Driver-Side Passenger-Side 59.0 61.0 62.0 68.0 68.0 N/A E-SERIES (February, 2011) 207 (Continued) 207 The statements below are applicable to the following incomplete vehicle types when equipped with untrimmed front seats: • Incomplete E-Series Van • Cutaway This vehicle when completed, will conform to Standard 207, Seating Systems, if: • No changes or modifications 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. • No modifications are made to the floor 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 specifications in Figure B for E-Series on page 26. 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. E-SERIES (February, 2011) 23 207 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, cannot be determined based upon the components supplied on 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. 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 28. 208 The statements below are applicable to the following incomplete vehicle types when equipped with 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 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. 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 modified. If the seat belt components are temporarily removed for any reason, they are reinstalled to the specifications for E-Series shown in Figure A on page 25 and Figure B on page 26. • 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 fit, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and – Latch mechanism requirements specified 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 specified by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system. 208 (Continued Next Page) STATEMENTS OF CONFORMITY 208 (Continued) • The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sunvisors 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 affixed 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 specified in Section 4.5.1(c) of Standard 208. Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard. • No actions are taken which would impair the integrity of the seat belt systems and the seat belt warning system. • The Air Bag Supplemental Restraint System as installed by Ford Motor Company (see Figure E on page 28) 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. • The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sunvisors are visible and not altered, modified, or removed. Any seat belt assemblies added to this vehicle 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 warning system, and attaching hardware installed by Ford Motor Company are not removed, relocated, altered, or modified. • 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 28) 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. 208 The statement below is applicable to the following vehicle type: • E-Series Basic (Stripped) Chassis Conformity with Standard 208, Occupant Crash Protection, cannot be determined based upon the components supplied on 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 supporting figures for FMVSS 208, on pages 23-31, are appropriate 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 OCCUPANT SUPPLEMENTAL RESTRAINT SYSTEM (AIRBAG(S), WIRING, AND SENSORS INCLUDING AN RCM UNDER DRIVER'S SEAT) AND PYROTECHNIC BUCKLE PRETENSIONER(S). DELETION OF FRONT PASSENGER ACCOMMODATIONS INCLUDING RESTRAINTS, SEAT, AND PEDESTAL COUPLED WITH THE ADDITION OF DELETE RESISTORS IN THE SENSOR SYSTEM CIRCUITRY IS AVAILABLE ON SOME VEHICLES. MODIFICATIONS TO THE VEHICLE FORWARD OF OR NEAR THE CRASH SENSORS SHOWN IN FIGURE E PAGE 28 MAY AFFECT THE DEPLOYMENT OF THE AIRBAG(S) AND PRETENSIONER(S). STATEMENTS OF CONFORMITY 24 E-SERIES (February, 2011) e to your vehicle [twond mounting positions valent, and torque all cifications shown for FRONT AND REAR SEAT LAP SHOULDER SAFETY BELT INSTALLATION INSTRUCTIONS ECONOLINE – 2008 AND FORWARD MODEL YEARS of all seat cushions, place any safety belt op Manual. ▼ 15602B90 COVER ASSEMBLY TION lts. pacers to be installed SAFETY BELT MENT SAFETY CARE MUST BE T ALL SAFETY D. ION ▼15602B82 ADJUSTER ASSEMBLY CUT-AWAY AND VAN MODELS ▼ 15602B82 ADJUSTER ASSEMBLY ▼15602B90 COVER ASSEMBLY UPPER PANEL ASSEMBLY CLOSE D-RING COVER AFTER INSTALLATION OF BELT ASSEMBLY CLOSE D-RING COVER AFTER INSTALLATION OF BELT ASSEMBLY TO FRONT OF VEHICLE ▼ W520113 ▼ TORQUE TO 40.0 ± 6.0 N·m ▼ NOTE 1, 2 TO FRONT OF VEHICLE ▼ W520113 ▼ TORQUE TO 40.0 ± 6.0 N·m ▼ NOTE 1, 2 ▼15611B09 BELT AND RETRACTOR ASSEMBLY lap safety belt and SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE ssengers, including e sure that lap belts nd the hips. If safety sk of you or your n greatly increases. retractors, buckles, lies (slide bar), (if so ers (if so equipped), if so equipped), and d after any collision. d unless a qualified damage and operate e during a collision d if either damage or ngues and belt and However, if a safety ollision, the belt and as the center adjust or the center adjust mbly. When replacing and buckles, center ctors, use only the Ford Master Parts of the vehicle being not be interchanged ever, they should be me damaged and that ASSEMBLY CUT-AWAY MODELS ONLY shoulder only. Never rm. Never swing it der. Failure to follow sk and/or severity of one person or across greatly increases the will be injured in a your vehicle has a is made up of one ned to be used as a ▼ 15611B08 BELT AND RETRACTOR B ▼ PIA BOLT ▼ TORQUE TO 47.5 ± 7.2 N·m ▼ NOTE 1, 2 VIEW A ▼ PIA BOLT ▼ TORQUE TO 47.5 ± 7.2 N·m ▼ NOTE 1, 2 PANEL ASSEMBLY COVER A SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE PANEL ASSEMBLY COVER CUT-AWAY MODELS ONLY VIEW OF FRONT SEAT LAP AND SHOULDER SAFETY BELTS USED WITH BUCKET SEAT OR CAPTAINS CHAIR (PASSENGER'S SIDE) ALL WAGON - VAN MODELS ONLY ▼ PIA BOLT ▼ TORQUE TO 47.5 ± 7.2 N·m ▼ NOTE 1, 2 VIEW A ▼ PIA BOLT ▼ TORQUE TO 47.5 ± 7.2 N·m ▼ NOTE 1, 2 A FIGURE 2 ATTENTION DEALERS CAUTION: Components installed Place this instruction sheet near trim panels in vehicle’sadjacent glove box after to belt installation restraint systemsafety components must remain clear of all trim panels. VIEW B VIEW OF FRONT SEAT LAP AND SHOULDER SAFETY BELTS USED WITH BUCKET SEAT OR CAPTAINS CHAIR (DRIVER'S SIDE) ALL WAGON - VAN MODELS ONLY ▼ THIS SYMBOL MEANS USE ONLY THE PART INDICATED. DO NOT SUBSTITUTE. ▼ NOTE 1: NO OMISSION OR SUBSTITUTION INSTALL AS SHOWN – SEQUENCE OF ASSEMBLY ▼ NOTE 2: TORQUE CONTROL – ALL TORQUE ▼ NOTE 3: ▼ NOTE 4: FIGURE 1 ▼ NOTE 5: CPR © 2006 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 9-06 REQUIREMENT MUST BE MAINTAINED AT INSTALLATION WITH FASTENERS SECURELY SEATED AVOID CONTAMINATION ASSURE THAT SEAT BELT WEBBING IS NOT TWISTED AT INSTALLATION FRONT SPIKE TEST (QT2021), REAR SPIKE TEST (QT3004) OR VSR BENCH TEST (QT2100) SK 8C24-15611B08-AA SHEET 1 OF 7 INTERIOR TRIM 9.5 RADIUS MIN. [.37 IN] RETRACTOR 12.5 MIN. [.50 IN] OVERLAP UP ADJUSTED POSITION 6.0 [.24 IN] 6.5 MIN. FROM [.25 IN] RELEASE KNOB TO INTERIOR TRIM 3.0 [.12 IN] 2.0 MIN. [.08 IN] (WITH DRING LOCATED ON SHLDR.BOLT) (3) FULL THREAD EXPOSED UP POSITION SECTION D 13.0 MIN. FROM [.50 IN] COVER TO RELEASE KNOB DOWN ADJUSTED POSITION VIEW IN CIRCLE C C 6.0 MIN. [.24 IN] A 6.0 MIN. CLEARANCE [.24 IN] AROUND BELT PERIPHERY AT MAX. TRAVEL POSITIONS A 1560262 REF. SEAT BEL T WEBBING B B D 6.0 MIN. [.24 IN] FRONT OF VEHICLE SECTION A 6.0 MIN. CLEARANCE [.24 IN] TO ALL ADJUSTED POSITIONS D MAIN VIEW NOTE: ALL DIMENSIONS ARE IN MILLIMETERS SECTION B [ ] DIMENSIONS ft-lb OR INCHES FIGURE A ­– E-SERIES FRONT SEAT RESTRAINT SYSTEM E-SERIES (February, 2011) 25 STATEMENTS OF CONFORMITY SEAT ASY. SEAT ASY. BUCKLE ASY. 15610E15 PIA BOLT TORQUE + 6.0 Nm 40.0 + 4 ft-lb] [29.5 - N801078 SCREW M8x1.25 HEX 4 REQ’D. TORQUE 25.0 + - 3.8 Nm [18.4 + - 2.8 ft-lb] N801078 SCREW M8 x 1.25 HEX 4 REQ’D. + 3.8 Nm TORQUE 25.0 [18.4 + 2.8 ft-lb] 15618B47 TRACK ASY. 1561701 POWER TRACK ASY. FRT. ST. PIA TO BUCKLE 15618B46 TRACK ASY. 56912 SCREW 4.2 x 19 TAPPING BUCKLE ASY. 15610E14 PIA BOLT TORQUE + 6.0 Nm 40.0 + 4 ft-lb] [29.5 - 1561755 HANDLE FRT. ST. TRACK 14A699 WIRE ASY. WIRING ASYSEAT CONTROL FEED JUMPER N800937 NUT & WASHER ASY. 2 REQ’D. TORQUE 55.0 + - 8.3 Nm [40.6 + 6 ft-lb] 14A701 SWITCH ASY. ST. CONTROL 611D02A STUD COVER 4 REQ’D. W705944 SCREW 2 REQ’D. + 8.3 Nm TORQUE 55.0 + 6 ft-lb] [40.6 - POWER L.H. SHOWN 56912 SCREW 4.2 x 19.0 TAPPING 1562506-A SUPPORT ASY. (R.H. MNL) 611D02A STUD COVER 4 REQ’D. N811326 SCREW 2 REQ’D. + 8.3 Nm TORQUE 55.0 + 6 ft-lb] [40.6 - N802351 STUD 2 REQ’D. 1560094-A/B SUPPORT ASY. COVER FRT. ST. PIVOT N620481 NUT M8 x 1.75 HEX FLANGE TORQUE 25.0 + - 3.8 Nm [18.4 + - 2.8 ft-lb] CHILD SEAT TETHER SLOTS N620432 M10 HEX NUT HD. NUT W/WASHER 4 REQ’D. N802351 STUD 2 REQ’D. MANUAL R.H. SHOWN E-SERIES DRIVER (L.H.) SEAT INSTALLATION PIA BOLT TORQUE + 6.0 Nm 40.0 + 4 ft-lb] [29.5 - E-SERIES PASSENGER (R.H.) SEAT INSTALLATION CLEARANCE ZONE 579988 SEAT 10 DR. 15610E14 PASS 15610E15 BUCKLE ASY. O 15 O PRE FOR SHIPPING PURPOSES ONLY, ONLY 4 SCREWS (NO NUTS & BOLTS) COVER FRT ST. PVT. 10 O CLEARANCE ZONE 45 O SS A 611D02A STUD COVER 4 REQ’D. DR. 1561704 R.H. TRACK N800937 NUT & WASHER ASY. SIDE VIEW 2 REQ’D. VIEW A 55.0 + - 8.3 Nm FRONT OF VEHICLE [40.6 + - 6 ft-lb] CENTER OF VEHICLE PRETENSIONER CLEARANCE ZONE W705944 SCREW 2 REQ’D. 55.0 + - 8.3 Nm + 6 ft-lb] [40.6 - DR. 1561705 L.H. TRACK 14A699 WIRE ASY. 1561755 (DR.) HDL.FRT.ST.TRK. REAR VIEW N011488 STUD 2 REQ’D. IMPORTANT: THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS. THE BUCKLE MOVES DOWNWARD THROUGH THE SHADED ZONE AND MUST NOT CONTACT ANY COMPONENT WHICH MAY DEGRADE ITS PERFORMANCE. DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREA, OR ALTER OR MODIFY THIS AREA. 1560094-A (MANUAL) SUPPORT ASY. [ ] DIMENSIONS ft-lb OR INCHES E-SERIES DRIVER (L.H.) SEAT DELETE OPTION FIGURE B – E-SERIES FRONT SEAT INSTALLATION STATEMENTS OF CONFORMITY 26 E-SERIES (February, 2011) SRP INFORMATION POINT A (SEAT POSITION IS 20 mm [0.78 IN] FORWARD OF REARMOST POSITION) (SEAT POSITION IS AT THE MIDPOINT OF AVAILABLE TRAVEL) A B C DRIVER – SEAT (VAN AND CUTAWAY) 217.8 113.0 385.3 [8.57] [4.45] [15.17] PASSENGER – SEAT (VAN AND CUTAWAY) 269.1 113.0 377.3 [10.59] [4.45] [14.85] D MIN. 356.0 [14.01] 412.0 [16.22] E MAX. 67.0 [2.64] 65.0 [2.56] F 937.4 [36.90] 960.1 [37.80] THE TORSO ANGLE IS DETERMINED BY USING THE METHOD SPECIFIED IN SAE J826 (JULY 1995) E E C L OUTSIDE FRONT FASTENER POINT A POINT A SEAT BASE D A 18 DRIVER & 18 PASSENGER TORSO ANGLE POINT A C SEAT BASE F B B 6.0 [0.24] CL FORWARD MOST OUTBOARD FRONT PASSENGER HEEL POINT PASSENGER SEAT 510.0 [20.08] SEAT BACK PIVOT DRIVER SEAT C L VEHICLE DRIVER SIDE ONLY IMPORTANT: 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. SRP HAS A 12.7 [0.50] RADIAL TOLERANCE PERMITTED FROM BASE SRP [ ] DIMENSIONS ARE INCHES FIGURE C – E-SERIES SEATING REFERENCE POINT (SRP) DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREAS, NOR ALTER OR MODIFY THESE AREAS FIGURE D – E-SERIES OCCUPANT PROTECTION ZONE E-SERIES (February, 2011) 27 STATEMENTS OF CONFORMITY INSTRUMENT PANEL HARNESS STEERING WHEEL DRIVER AIRBAG PASSENGER AIRBAG READINESS INDICATOR RESTRAINTS CONTROL MODULE (ON FLOOR UNDER DRIVER SEAT) CONNECTOR AT SAFETY WALL FRONT CRASH SENSOR ENGINE COMPARTMENT HARNESS DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS THAT ARE IDENTIFIED IN THIS ILLUSTRATION. FIGURE E1 – E-SERIES SUPPLEMENTAL RESTRAINT SYSTEM (Air Bags, Sensors, and Wiring) FIGURE E2 – E-SERIES RESTRAINT CONTROL MODULE 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. 14B321 SNS & BRKT ASY - A/BAG FRT W707935 SCREW TORQUE 12.0 ± 1.8 Nm [9 ± 1.3 ft-lb] 14405 WIR ASY - RR LP REF FRONT FLOOR PAN FRONT OF VEHICLE FIGURE E3 – E-SERIES RESTRAINT CONTROL MODULE STATEMENTS OF CONFORMITY 28 E-SERIES (February, 2011) CUT LINE CUT LINE CUT LINE SECTION C SECTION B CUT LINE CUT LINE SECTION A SECTION D 711.2 [ 28.00 ] MAXIMUM 711.2 [ 28.00 ] MAXIMUM THE SPOTWELDS (X) IN THIS B AREA MUST REMAIN INTACT. B A A C C D D FRONT OF VEHICLE 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. [ ] DIMENSIONS ARE INCHES FIGURE F1 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (DRIVER SIDE – L.H.) E-SERIES (February, 2011) 29 STATEMENTS OF CONFORMITY CUTLINE SECTION F CUTLINE CUTLINE SECTION G SECTION E THE SPOTWELDS ( X ) IN THIS AREA MUST REMAIN INTACT. F F 533.4 [21.00] MAXIMUM WITH SLIDING DOOR E E G 711.2 [28.00] MAXIMUM WITH CARGO DOORS G FRONT OF VEHICLE 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. [ ] DIMENSIONS ARE IN INCHES FIGURE F2 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (PASSENGER SIDE – R.H.) STATEMENTS OF CONFORMITY 30 E-SERIES (February, 2011) END OF ROOF EXTENDED VAN END OF ROOF REGULAR VAN OUTER EDGE OF TROUGH END OF ROOF CUTAWAY CL "B" PILLAR REINFORCEMENT 50.8 [2.00] WINDSHIELD HEADER 203.2 [8.00] SECTION AT CL OF ROOF FORWARD CUT LINE CUT LINE REGULAR VAN 203.2 [8.00] CUT LINE 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 VEHICLE [ ] DIMENSIONS ARE INCHES NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. FIGURE F3 – ROOF PANEL REMOVAL AREA – E-SERIES E-SERIES (February, 2011) 31 STATEMENTS OF CONFORMITY 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 specified in Section 4.1 (b), (c), (e), (g), and (h), respectively, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with these requirements of Standard 209. However, Ford Motor 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 paragraphs of the standard not specified above, provided no alterations or replacements are made to the seat belt assemblies and attaching hardware, as provided by Ford Motor Company, and 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 conform 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, cannot be determined based upon the components supplied on 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. STATEMENTS OF CONFORMITY 32 210 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 alterations are made to the front seat belt anchorages, front seat belt assemblies, floor pan, floor pan reinforcements, or body mounts. • E-Series window or roof modifications do not exceed the defined cut out areas shown in Figures F1, F2 and F3 on pages 29, 30, and 31. 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 27. The Incomplete E-Series Van, Wagon, and Cutaway must have a seat belt anchorage system installed for each additional designated seating position that conforms to the applicable requirements of this Standard. The Incomplete E-Series Recreational Van or the ESeries Wagon may have additional 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 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. 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, cannot be determined based upon the components supplied on this incomplete vehicle; a c c o r d i n g l y, Fo r d M o t o r C o m p a ny m a ke s n o representation as to conformity with this Standard. E-SERIES (February, 2011) 210.1 Canadian Requirements: 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. The statement below is 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 210.1, 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 floor 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. 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 modified in any way except as specified in this manual: – Windshield and windshield mounting system – Cab and front end structural components including the roof, pillars, cowl, cowl reinforcements, hood, doors, fenders, hood restrictors and apron reinforcements, and frame and frame 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 modification made to the incomplete vehicle as manufactured by Ford Motor Company and no components or structure installed by a subsequent stage manufacturer results in any loss of windshield retention (as defined in Standard 212) or any penetration of the inner surface of the windshield or intrusion into the protected zone (as defined in Standard 219) when the vehicle is impacted in any manner specified 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 14 corresponding to the vehicle's model and wheelbase. 210.2 Canadian Requirements: The statement below is 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. 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. † 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 (February, 2011) 33 STATEMENTS OF CONFORMITY 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. 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 definition on page 5. 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. 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 217, Bus Window Retention and Release, if no alterations, modifications, or replacements are made to the doors, window glazing materials, window mounting systems, or the surrounding door structure as provided by Ford Motor Company. Any windows, doors, additional 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, cannot be determined based upon the components supplied on 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 Section 5.1 requirements of this Standard if no modifications, 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: The preceding statements for FMVSS 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. 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. 213 214 214 The statement below is applicable to all incomplete vehicle types: Conformity with Standard 213, Child restraint systems, cannot be determined based upon the components supplied on 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. 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, modifications, 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 modifications do not exceed the defined cut out areas shown in Figure F1, F2 and F3 on pages 29, 30, and 31, respectively. 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 structure, 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, modifications, 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. STATEMENTS OF CONFORMITY 34 E-SERIES (February, 2011) 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 first 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 Standard. 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, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard. 225 The statement below is 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 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 floor pan, or floor pan reinforcements, 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. E-SERIES (February, 2011) 35 301 Note The terms “body” or “body structure”, 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 The Unloaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of FMVSS 301. Completed vehicles manufactured by Ford Motor Company that are tested to demonstrate compliance with FMVSS 301 are loaded pursuant to S7.1.6 of the Standard. The test weights of these vehicles comprise the Unloaded Vehicle Weights including the weights of all available regular production options plus the loads specified by S7.1.6. These test weights are less than the respective designated Gross Vehicle Weight Ratings. In addition to the specific 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 statements pertaining to particular incomplete vehicle types, the statements immediately below 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 non-metallic 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 modified 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 – Fuel filler cap, pipe(s), hose(s), any provided protective wrap, and attachment hardware – Fuel lines, routing, and attachments – Vapor lines and carbon canister – (gasoline engine only) – Fuel pump – Fuel filter – Fuel pump relay (gasoline engine only) – Fuel shut-off switch (fuel pump relay) 301 (Continued Next Page) STATEMENTS OF CONFORMITY 301 (Continued) Note: Crossmember Installation • 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 for E-Series on page 14 corresponding to the incomplete vehicle’s model and wheelbase. • Required part will be provided, but not installed in vehicle position. • Crossmember will be shipped in a temporary position on top of rear frame rail. Permanent installation hardware will be included in dunnage box. • Crossmember may not be located closer to fuel tank than design position shown in Figures G1 and G2. – The four Required Frame Holes must be drilled to size, location, and orientation on frame as specified in Figure H1 (E-350 School Bus only). – The E-350 SRW rear bumper is manufactured and installed to the specifications found in Figure H2 (E-350 School Bus only). • School bus requires use of Ford-supplied body mounts or equivalent • 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 (by following structural and package guidelines illustrated in Figure I) that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301, (a) body components and attaching hardware 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 system 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 specified by applicable provisions of Standard 301. – The fuel filler cap, pipe(s), hose(s) and attachment hardware are installed as shown in Figure J for E-250/350 vehicles. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301. – The fuel filler cap, pipe(s), hose(s) and attachment hardware are installed as shown in Figure K for E-350/450 vehicles. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301. – Body installations using flexible attaching systems require use of a flexible/adjustable attachment in conjunction with a shear plate, both mounted aft of the fuel tank. Flexible/adjustable attachments located within 10 inches of the rear surface of the fuel tank are required to be either an inverted U-bolt, a J-hook, or a chassis clamp. 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. 301 The statements below are applicable to the following incomplete vehicle types: • Cutaway (GVWR of 4536 kg [10,000 lb] or less) • E-Series Cutaway (SRW) with 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 modified in any way except as specified in the following representations: – Fuel tank(s) and attachment hardware including sending unit, vapor valve, fuel tank shield, fuel tank surface patch, pressure transducer and in-tank electric fuel pump – Fuel filler cap, pipe(s), hose(s), any provided protective wrap, and attachment hardware – Fuel lines, routing, and attachments – Vapor lines and carbon canister – (gasoline engine only) – Fuel pump – Fuel pump relay (gasoline engine only) – Fuel filter – Fuel shut-off switch (fuel pump relay) – The two Outboard Frame Reinforcements, two Lower Frame Flange Reinforcements, one Upper Frame Flange Reinforcement, and two extra Back-To-Back Crossmembers, shown in Figures G1 and G2, used in the SRW School Bus Preparation Package. – Required rear crossmembers must be installed either in design positions as shown in Figure G using torque values from SVE Bulletin Q-182 or in alternate locations shown in SVE Bulletin Q-184. Additional installation information available in Ford Shop Manual or by contacting Body Builders Advisory Service. † 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 301 36 (Continued Next Page) E-SERIES (February, 2011) OUTBOARD FRAME REINFORCEMENT (SRW ONLY) NO MODIFICATIONS NO ATTACHMENTS BACK-TO-BACK CROSSMEMBERS (SRW ONLY) REQUIRED FRAME HOLES (E-350 ONLY – REFER TO FIGURE H1 FOR DETAILS) REQUIRED CROSSMEMBER (SRW ONLY) LOWER (2) AND UPPER (1) FRAME FLANGE REINFORCEMENTS (SRW & DRW) FIGURE G1 – E-SERIES CUTAWAY WITH SCHOOL BUS PREPARATION PACKAGE TUBULAR STYLE LOWER C/M HAT-SECTION STYLE LOWER C/M REQUIRED CROSSMEMBERS • E-350 SRW 138" WB CUTAWAY W/ SCHOOL BUS PREP PACKAGE REQUIRED CROSSMEMBERS • E-350 138" WB CUTAWAY W/O SCHOOL BUS PREP PACKAGE HAT-SECTION STYLE LOWER C/M 40 GALLON ONLY TUBULAR STYLE LOWER C/M REQUIRED CROSSMEMBERS • E-350 158" WB CUTAWAY W/O SCHOOL BUS PREP PACKAGE REQUIRED CROSSMEMBERS • E-350 176" WB CUTAWAY W/O SCHOOL BUS PREP PACKAGE FIGURE G2 – E-350 CUTAWAY REQUIRED REAR CROSSMEMBERS FOR SRW SCHOOL BUS PREPARATION PACKAGE OR GVWR OF 4536 KG [10,000 LB] OR LESS 301 (Continued) 301 • 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 14 corresponding to the model and wheelbase. † 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. 301 E-SERIES (February, 2011) 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, cannot be determined based upon the components supplied on this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this standard. 37 (Continued Next Page) STATEMENTS OF CONFORMITY SCHOOL BUS ONLY L = minimum frame length from body mount hole 385 mm [15.2 in] R = required frame holes position from end of frame 175 +/- 25 mm [6.9 +/- 1.0 in] FIGURE H1 – E-350 CUTAWAY WITH SCHOOL BUS PREPARATION PACKAGE BUMPER WIDTH TO SUIT BODY WIDTH; BUMPER WRAPS AROUND CORNER WITH MINIMUM DIMENSIONS AS SHOWN ALUMINUM BUMPER 4.7 mm [0.2 in] 203 mm [8.0 in] BRACKETS MINIMUM HSLA 350 2.0 mm [0.08 in] USE MINIMUM 51 mm [2.0 in] OVERLAP FRAME RAIL. USE 1/2" BOLTS GR5 FOR ATTACHMENTS. TORQUE 95 Nm [70 LB FT] 305 mm [12.0 in] FIGURE H2 – E-350 SRW CUTAWAY WITH SCHOOL BUS PREPARATION PACKAGE Maintain minimum of 50 mm [2.0 in] gap between the highest point on top of fuel tank, including fuel system components, to body structure including floor pan and body crossmembers. There shall be no sharp edges or fasteners pointing towards tank in any direction. Local 305 mm [12.0 in] long plate reinforcements (doublers) using 1.9 mm (Gage 14) commercial quality galvanized sheet metal at body mount locations. Body mount spacers require full length continuous welds to crossmembers. Attach body crossmember flanges using 38 mm [1.5 in] spaced spot welds, self-tapping screws 76 mm [3.0 in] apart, or ¼" blind rivet fasteners 76 mm [3.0 in] apart. Minimum commercial quality galvanized sheet metal thickness 1.9 mm [0.8 in] (Gage 14) for rear under body crossmembers. FIGURE I – E-350 SRW CUTAWAY WITH SCHOOL BUS PREPARATION PACKAGE STATEMENTS OF CONFORMITY 38 E-SERIES (February, 2011) APPENDIX 1 ` Rear suspension Cross Member and Aft-of Fuel Tank Cross Member – 138 in./158 in. Wheelbase 2 103 Nm (76 lb-ft) 2 103 Nm (76 lb-ft) For see the 2010 E-SeriesIncomplete IncompleteVehicle Vehicle Manual Manual available available at: at: E-Series 2010 the please details,please Furtherdetails, For further www.fleet.ford.com/truckbbas in the "PUBLICATIONS" section. APPENDIX 1 Originator: BBAS Q-182 –R!1 Page 4 of 5 Date Issued: 04 Sept, 2009 Date Revised: 22 Jan 2010 SVE BULLETIN Q-182 PAGE 4 – REQUIRED REAR CROSSMEMBER TORQUE VALUES – HAT-SECTION STYLE E-SERIES (February, 2011) 39 Wheelbase in.in. 138/176 in./176 Wheelbase Rear suspension Cross Member and Aft-of Fuel Tank Cross Member – 138 2 103 Nm (76 lb-ft) 3 81 Nm (60 lb-ft) 5 150 Nm (110 lb-ft) For further details, please see the 2010 E-Series Incomplete Vehicle Manual available at: For Further details, please the 2010 E-Series Incomplete Vehicle Manual available at: www.fleet.ford.com/truckbbas in the "PUBLICATIONS" section. Originator: BBAS Q-182 –R!1 Page 5 of 5 Date Issued: 04 Sept, 2009 Date Revised: 22 Jan 2010 SVE BULLETIN Q-182 PAGE 5 – REQUIRED REAR CROSSMEMBER TORQUE VALUES – TUBULAR STYLE 40 E-SERIES (February, 2011) Q-184 SVE BULLETIN SPECIAL VEHICLE ENGINEERING – BODY BUILDERS ADVISORY SERVICE E-Mail via website: www.fleet.ford.com/truckbbas (click "Contact Us") Toll-free: (877) 840-4338 QVM Bulletin: Q-184 Date: 11 Nov., 2009 Alternative Cross Member Locations For E-Series Second Unit Bodies This letter amends the 2010MY E-Series Compliance Demonstration Report Package by making Post Job #1 revisions to the Incomplete Vehicle Manual to allow more alternatives for mounting the second unit bodies to the Ford E-Series Cutaway & Stripped Chassis. Additional flexibility, related to frame rail extension and frame cross member location, is provided while still maintaining Ford pass-through compliance for F/CMVSS 301. The agreed upon changes affect only – E350 C/A & Stripped Chassis, 10K GVWR and below Incomplete Vehicle, Non-School Bus, 138"/158"/176" WB, Single/Dual Rear Wheel Applications. Additional Dimensions For Cross members and Frame: (Reference Diagram A and Table 1 for more details) 1. The revisions allow the FSM to use either the #7A Hat Section or #7B Tubular Cross member in any Non-School Bus application that requires a #7 cross member. They also provide guidelines for acceptable mounting locations of the #7 and #8 cross members and for frame rail extension. 2. "K" dimension is added to provide a minimum dimension of the #7A or #7B from the rear edge of the fuel tank flange to the rear surface/edge of the cross member. 3. "M" dimension is added to specify the maximum allowable frame stretch length aft of the #7A or #7B cross member. The measurement is from the rear surface of the #7 cross member to the end of the frame rail. 4. "S" dimension is added to specify alternative locations of the #8 cross member. The measurement is from the design location to a maximum allowable forward position. The #8 cross member may be located anywhere within the "S" dimension. Note: If either cross member is relocated, the corresponding cross member must be moved simultaneously, in keeping within dimension "K". Originator: BBAS Q-184 Page 1 of 2 Date Issued: 11 Nov, 2009 Date Revised: SVE BULLETIN Q-184 PAGE 1 OF 2 – REQUIRED REAR CROSSMEMBER ALTERNATIVE MOUNTING LOCATIONS E-SERIES (February, 2011) 41 NON-SCHOOL BUS APPLICATIONS (Diagram A) #8 CM #7B CM K M (Note: Tubular Type Cross Member shown) S NON-SCHOOL BUS APPLICATIONS (TABLE 1) Min. Clearance "K" of #7 CM (as measured from rear vertical surface of cross member) Hard Mounted Body Applications Rubber Body Mount Applications Tubular (#7B CM) HatSection (#7A CM) 12.5" (318 mm) 31.9" (810 mm) Current Design Location Current Design Location 15.9" (405 mm) 31.9" (810 mm) Current Design Location Current Design Location Max. Frame Extension "M" Tubular (#7B CM) 15" (380 mm) 18.3" (465 mm) HatSection (#7A CM) 15" (380 mm) 18.3" (465 mm) Distance "S" that #8 CM Can Be FW of Design Loc. Tubular (#7B CM) Hat-Section (#7A CM) 180 mm 220 mm FW of Design Position FW of Design Position 180 mm 220 mm FW of Design Position FW of Design Position Cross Member Part Numbers Part Number AC24-5060-DA Description Tubular AC24-5060-AA Hat Section Originator: BBAS Q-184 DRAFT Usage before this TSB SRW Schoolbus and 176" Non Schoolbus C/A Carry over Page 2 of 2 Usage after TSB SRW Schoolbus & All non-schoolbus appl's (if desired, must meet reqmt's) All non-schoolbus appl's (if desired, must meet reqmt's) Date Issued: 11 Nov, 2009 Date Revised: SVE BULLETIN Q-184 PAGE 2 OF 2 – REQUIRED REAR CROSSMEMBER ALTERNATIVE MOUNTING LOCATIONS 42 E-SERIES (February, 2011) 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 provisions of 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. – Body installations using flexible attaching systems require use of a flexible/adjustable attachment in conjunction with a shear plate, both mounted aft of the fuel tank. Flexible/adjustable attachments located within 10 inches of the rear surface of the fuel tank are required to be either an inverted U-bolt, a J-hook, or a chassis clamp. • 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 specified by applicable provisions of Standard 301. • The E-Series Basic (Stripped) Chassis aft-of-axle fuel filler cap, pipe, hose(s), and attaching hardware are installed as shown in Figure K. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified 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 modified in any way. 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 specified by Section 7.1.6 of the Standard. The tested vehicles met the applicable requirements of Standard 301. This vehicle, when completed, is capable of compliance with Standard 301, Fuel System Integrity, if: • The following fuel system components as installed by Ford Motor Company are not removed, relocated, altered, or modified in any way except as specified in the following representations: – Fuel tank and attachment hardware, including sending unit, vapor valve, OBD II pressure transducer, fuel tank shield, fuel pump relay, and in-tank electric pump – Fuel filler cap, pipe(s), hose(s), any provided protective wrap, and attachment hardware – Fuel lines, routing, and attachments – Vapor line(s) and carbon canister – Fuel filter – Fuel fuel pump relay • No other alteration or modification 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 specified 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 14 corresponding to the model, and wheelbase. † 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. 560.2 [22.06] MAX TOP OF FILLER PIPE SUPPORT W711103-S900 SCREW (3 REQ’D) 0.9-1.3 Nm [8-11 in-lb] 301 (Continued on next page) OUTSIDE SURFACE OF FRAME RAIL FRONT OF VEHICLE FUEL FILL TUBE TO BE LOCATED WITH 0.0 OFFSET TO FUEL TANK CONNECTOR ROUTE FILL AND VENT HOSES SO NO LOW SPOTS OCCUR FUEL TANK (TYPICAL) 359.4 [14.15] MIN FUEL TANK FILL PIPE (TYPICAL) Maintain minimum of 50 mm [2.0 in] gap between the highest point on top of fuel tank, including fuel system components, to body structure including floor pan and body crossmembers. There shall be no sharp edges or fasteners pointing towards fuel tank. Second Unit Body to be installed with a maximum dimension of 140 mm [5.5 in] from top of frame upper flange to bottom of box load floor. NOTES: FACE OF FILLER PIPE SUPPORT TO BE INSTALLED ON BODY IN VERTICAL PLANE TOP OF FRAME RAIL N611131-S439 M4 SELF-TAPPING SCREW (ATTACH TO SOUND METAL ON FRAME) TORQUE ALL WORM GEAR-DRIVEN HOSE CLAMPS TO 2.9 - 4.3 Nm [25 - 38 in-lb] SECURE WITH TIE STRAPS AS REQ’D TO VENT HOSE [ ] DIMENSIONS ARE INCHES CRITICAL CONTROL ITEM W611645-S439 M10 SELF-TAPPING SCREW FIGURE J – E-250/350 CUTAWAY FUEL FILLER PIPE INSTALLATION FOR MID-SHIP FUEL TANK E-SERIES (February, 2011) 43 STATEMENTS OF CONFORMITY 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 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 modified in any way except as specified in the following representations: – Fuel tank and attachment hardware, including sender unit, vapor valve, fuel tank shield and fuel tank surface patch – Fuel filler cap, pipe(s), hose(s), any provided protective wrap, and attaching hardware – Fuel pump – Fuel filter – Fuel water separator, fuel filter/primer, fuel line heater, and injection pump – Fuel shut-off switch (fuel pump relay) – The two Lower Frame Flange Reinforcements and one Upper Frame Reinforcement – The Required Frame Holes must be drilled to size, location, and orientation on frame as specified in Figure H1 (E-350 only). – Requires use of Ford-supplied body mounts or equivalent TO BACK OF CUTAWAY CAB FRONT OF VEHICLE • The completed vehicle when loaded to the requirements of Section 7.1.6 (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 specifications found in Figures L1 and L2. • The fill hoses, hose clamps, ground strap, and fuel sender unit must be installed to the specification on Figure K. • 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.† 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. † 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. Maintain minimum of 50 mm [2.0 in] gap between the highest point on top of fuel tank, including fuel system components, to body structure including floor pan and body crossmembers. There shall be no sharp edges or fasteners pointing towards fuel tank. TO CL OF REAR CL OF FILLER NECK AXLE FOR STRIPPED CHASSIS OUTBOARD SURFACE ALL WB OF FRAME RAIL 601.4 + 12.7 + [23.7 0.5] 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.) W711103-S900 SCREW (3 REQ’D) TORQUE TO 0.9-1.3 Nm [8-11 in-lb] TOP OF FILLER PIPE SUPPORT NOTES: FACE OF FILLER PIPE SUPPORT TO BE INSTALLED ON BODY IN VERTICAL PLANE FUEL TANK (TYPICAL) TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 2.9 - 4.3 Nm [25 - 38 in-lb] SECURE WITH TI E STRAPS AS REQUIRED TO VENT HOSE A* [ ] DIMENSIONS ARE INCHES = FUEL SYSTEM FILLER HEIGHT * A- SCHOOL BUS: 395 [15.6] MINIMUM - OTHER: 319 [12.6] MINIMUM CALIFORNIA POINT Z SEE PAGE 47 CRITICAL CONTROL ITEM FUEL TANK FILL PIPE (TYPICAL) ROUTE FILL AND VENT HOSES SO NO LOW SPOTS OCCUR N611131-S439 M4 SELF-TAPPING SCREW N611645-S439 M10 SELF-TAPPING SCREW (ATTACH TO SOUND METAL ON FRAME) 9A099 GROUND STRAP FUEL TANK 40.2 [1.583] EXISTING 9.7 DIA. HOLES (USED FOR EXHAUST ON R.H. SIDE) FIGURE K – E-350/450 CUTAWAY AND BASIC (STRIPPED) CHASSIS FUEL FILLER PIPE INSTALLATION FOR AFT-OFAXLE FUEL TANK STATEMENTS OF CONFORMITY 44 E-SERIES (February, 2011) ITEM 1 2 3 PART NAME SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. SUPPORT – BODY ISOLATOR TO CROSS SILL R.H. BRACKET – SPACER FOR ISOLATOR SUPPORT TO FRONT CROSS SILL BRACKET – SPACER FOR ISOLATOR SUPPORT TO SECOND CROSS SILL SILL – FRONT CROSS SILL – SECOND CROSS SILL – THIRD & FOURTH CROSS GUSSET – CROSS SILL TO OUTER SUPPORT L.H. GUSSET – CROSS SILL TO OUTER SUPPORT R.H. SUPPORT – CROSS SILL OUTER L.H. SUPPORT – CROSS SILL OUTER R.H. BUMPER – REAR BRACKET – BUMPER TO FRAME L.H. BRACKET – BUMPER TO FRAME R.H. FLOOR HOUSING – FUEL FILL NECK CORNER BRACE – BUMPER TO FRAME 4 5 6 7 8 9 10 11 12 13 14 15 16 17 MATERIAL 6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL QUANTITY 1 1 2 6.35mm [0.25] HRLC STEEL 2 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 3.0mm [0.120] 11 GA. HRLC STEEL 3.0mm [0.120] 11 GA. HRLC STEEL 4.7mm [0.187] HRLC STEEL 6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 5.3mm [0.21] 5 GA. HRLC STEEL 1 1 2 4 4 1 1 1 1 1 1 1 2 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 Item 5 to 15 Item 6 to 15 Item 7 to Item 15 Item 5 to Items 8 or 9 Item 6 to Items 8 or 9 Item 7 to Items 8 or 9 Items 8 or 9 to Items 10 or 11 Item 16 FORD PROVIDED 12.0mm BOLT (6 REQ’D) TORQUE 70Nm [52 LB FT] 1318.3 [51.90] 25.4 [1.00] TYPICAL 16 2375.0 [93.5] MINIMUM 778.8 [30.66] 161.4 [6.35] SPACING / LOCATION 101.6mm [4.00] centers on front and rear flange – 50.8mm [2.00] stagger on front and rear flange 50.8mm [2.00] centers 101.6mm [4.00] centers 101.6mm [4.00] centers staggered top to bottom of cross-sill 101.6mm [4.00] centers staggered top to bottom of cross-sill 3 fasteners are 76.2mm [3.00] centers 50.8mm [2.00] centers NUMBER OF FASTENERS 48 estimated 48 estimated 47 estimated 6 6 6 3 on vertical side of item 10 or 11, 1 on bottom flange 9 9 12.8 [.50] 7 6 268.0 [10.55] 164.3 [6.47] 2 8 5 9 1 147.8 [5.82] 7 163.8 [6.45] 11 8 114.5 [4.50] 9 4 15 THE FUEL FILLER HOLE IN ITEM #15 (FLOOR) MUST BE 3.0 [.12] LARGER THEN BASE OF ITEM #16 3 10 MAY BE REMOVED TO ACCOMMODATE 8 WHEELHOUSE CLEARANCE 357.1 [14.06] 2438.4 [96.00] 1/2” BOLT, WASHERS & NUT GR5 TORQUE 95Nm [70 LB FT] 14.0 x 28.0 [.55 x 1.10] MAX 2 SLOTS IN ITEM #12,13,& 14 12 14 241.3 [9.50] 13 162.1 [6.38] EXISTING SLOT EXISTING FRAME HOLES SEE VIEW A FOR BUMPER CORNER BRACE INSTALLATION 228.6 [9.00] FORD PROVIDED ISOLATORS (6) 101.6 [4.00] 50.8 [2.00] [ ] DIMENSIONS ARE INCHES FIGURE L1 – E-SERIES DRW SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE E-SERIES (February, 2011) 45 STATEMENTS OF CONFORMITY 17 TOP VIEW OF FRAME & BUMPER 355.6 [ 14.00 ] E-450 BUMPER CORNER BRACE 1/2” BOLTS, WASHERS & NUTS GR5 TORQUE 95Nm [70 LB FT] VIEW A 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. 7 36.1 [ 1.42 ] 71.6 [ 3.13 ] 851.6 [ 33.53 ] CL RAIL B 5 425.8 [ 16.76 ] 170.0 [ 6.69 ] 42.7 [ 1.68 ] 36.7 [ 1.44 ] 170.0 [ 6.69 ] 122.0 [ 4.80 ] 48.0 [ 1.89 ] 18.0 [ 0.71 ] 32.1 [ 1.26 ] 85.0 [ 3.35 ] 74.0 [ 2.91 ] 37.0 [ 1.46 ] 110.0 [ 4.33 ] C L SEE VIEW C FOR HOLE DIMENSIONS LOCATION 28.1 C L [ 1.11 ] 3 46.5 [ 1.83 ] 26.9 [ 1.06 ] 98.0 [ 3.86 ] 125.0 [ 4.92 ] CORNERS ON BRACKETS – MINIMUM 12 mm [0.5] RADIUS AND NO SHARP EDGES. 34.9 [ 1.37 ] 38.6 [ 1.52 ] 13.0 [ 0.51 ] DIA 4 HOLES 14.0 [.55] DIA HOLE 134.0 [ 5.28 ] 13.0 [ 0.51 ] DIA 8 HOLES 110.0 [ 4.33 ] C L CL 4 32.6 [ 1.28 ] 6 40.3 [ 1.59 ] 138.8 [ 5.46 ] 172.0 [ 6.77 ] CORNERS ON BRACKETS – MINIMUM 12 mm [0.5] RADIUS AND NO SHARP EDGES. 13.0 [ 0.51 ] DIA 4 HOLES M12 BOLT & NUT GC 10.9 TORQUE 70 Nm [52 LB FT] M12 BOLT & NUT GC 10.9 TORQUE 70 Nm [52 LB FT] 985.6 C [ 38.80 ] TO L OF 36.0 DIA HOLE 492.8 C [ 19.40 ] TO L OF SILL 102.2 [ 4.02 ] 36.0 [ 1.42 ] DIA 2 HOLES 200.0 [ 7.87 ] 42.7 [ 1.68 ] 320.0 [ 12.60 ] 134.0 [ 5.28 ] 8.0 49.2 [ 0.31 ] [ 1.94 ] 1318.3 [ 51.90 ] 46.8 [ 1.84 ] 13.0 [ 0.51 ] DIA 8 HOLES 67.0 [ 2.64 ] 10 VIEW B SUPPORT CROSS SILL OUTER L.H. SHOWN. R.H. SYMETRICALLY OPPOSITE. TRIM WITH 45 o ANGLE TO REMOVE SHARP CORNER RELIEF TO PROVIDE MINIMUM 12 mm [0.50] CLEARANCE TO FILLER PIPE 1303.1 [ 51.30 ] 102.0 [ 4.02 ] 111. 0 [ 4.37 ] FRONT OF VEHICLE 60.4 [ 2.38 ] ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2 ON ALL 4 EDGES. 304. 8 [ 12.00 ] 24.8 [ 0.98 ] CL 552.4 [21.78] 46.2 [ 1.82 ] 15.0 [ 0.59 ] 571.7 [ 22.51 ] 1168.4 [ 46.00 ] 1 44.5 [ 1.75 ] 9 23.1 [ 0.91 ] 177.5 [ 6.99 ] WELD SHEET METAL RELIEF AFTER FORMING 104.8 [ 4.13 ] SUPPORT BODY IS0LATOR TO CROSS SILL L.H.SHOWN. R.H. SYMETRICALLY OPPOSITE (EXCEPT FOR RELIEF) GUSSET CROSS SILL TO OUTER SUPPORT R.H. SHOWN L.H. SYMETRICALLY OPPOSITE. [ ] DIMENSIONS ARE INCHES FIGURE L2 – E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE (OVER 4536 KG [10,000 LB] GVWR) STATEMENTS OF CONFORMITY 46 E-SERIES (February, 2011) Part 393.67 301.1 The statement below is applicable to all incomplete vehicle types: This incomplete vehicle does not comply with CMVSS Standard 301.1, LPG Fuel System Integrity. Ford Motor Company makes no representation as to conformity with this Standard. 301.2 The statement below is applicable to all incomplete vehicle types: This incomplete vehicle does not comply with CMVSS Standard 301.2, CNG Fuel System Integrity. Ford Motor Company makes no representation as to conformity with this Standard. 302 Part 565 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform 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 flammability 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, cannot be determined based upon the components supplied on 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. 303 U.S. Requirements: 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 vehicles, when completed, will conform to Standard 1106, Noise Emissions, Section 4, if noise control devices or elements of design are not modified 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, muffler, outlet pipe, resonator and diffuser. • Engine cooling fan and cooling fan clutch. The statement below is applicable to all incomplete vehicle types: This incomplete vehicle does not comply with Standard 304, Compressed Natural Gas Fuel Container Integrity. Ford Motor Company makes no representation as to conformity with this Standard. The statement below is applicable to all incomplete vehicle types: This incomplete vehicle does not comply with Standard 403, Platform Lift Systems for Motor Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. 404 The statement below is applicable to all incomplete vehicle types: This incomplete vehicle does not comply with Standard 404, Platform Lift Installations in Motor Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. E-SERIES (February, 2011) U.S. Requirements: This vehicle, when completed, will conform to Part 565 Vehicle Identification Number, if the vehicle identification number printed on the label affixed to the cover of this manual is mounted and displayed in accordance with the requirements of this Standard. 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 vehicles, when completed, will conform to Standard 1106, Noise Emissions, Section 2, if noise control devices or elements of design are not modified 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, muffler, outlet pipe, resonator and diffuser. • Engine cooling fan and cooling fan clutch. U.S. Requirements: 403 The 55 gallon fuel tank supplied on an E-Series Stripped Chassis and Cutaway will conform to the Part 393.67, Parts and Accessories Necessary for Safe Operation – Liquid Fuel Tanks, if the fuel tank as provided by Ford Motor Company is not altered on the completed vehicle. 1106 Canadian Requirements: The statement below is applicable to any School Bus Prep Package regardless of GVWR and to any other incomplete vehicle type if the GVWR Is 4536 kg [10,000 lb] or less: This incomplete vehicle does not comply with Standard 303, Fuel System Integrity of Compressed Natural Gas Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. 304 Parts and Accessories Necessary for Safe Operation – Liquid Fuel Tanks 47 STATEMENTS OF CONFORMITY CANADIAN VEHICLES (Vehicles to be completed for sale or use in Canada) VEHICLE IDENTIFICATION More specifically: Refer to the “Vehicle Description” section of this manual 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. • 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. DAYTIME RUNNING LAMP (DRL) • Replacement spark plugs, ignition wires, and ignition coils must be equivalent in their RFI suppression properties to original equipment. • Shields on ignition coils must remain installed. Compliance representations for CMVSS 108, Lighting and CMVSS 108.1, Headlamps, are in the “Statements of Conformity” section of this manual. The following items are also required for CMVSS 108 and 108.1 compliance: • Electrical grounds on all components must be retained. • Metallic components installed on the body or chassis must be grounded to the chassis. • The DRL circuits in the Smart Power Distribution Junction Box (SPDJB) are not to be altered. • The SPDJB module is not to be repositioned. • Electrical circuits added to the vehicle must not be installed near the high voltage ignition components. • The E-Series Basic (Stripped) Chassis, when equipped with a SPDJB module configured for Daytime Running Lamps as provided by Ford Motor Company, is designed only for a two headlamp system. • 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 compartment wiring must not be rerouted in any manner. CANADIAN RADIO FREQUENCY INTERFERENCE (RFI) INFORMATION • The Powertrain Control Module (PCM) must not be relocated from the position as installed by Ford Motor Company. 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-M06”. Violation of these regulations is punishable by fine 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 modifications 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. Additional guidance for installing two-way mobile radios can be found via the web at www.fordemc.com/docs/download/ Mobile_Radio_Guide.pdf. 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. STATEMENTS OF CONFORMITY 48 E-SERIES (February, 2011) EMISSION CERTIFICATION INFORMATION CAUTION: IMPORTANT: U.S.: 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 specified by Ford are not exceeded. If these restrictions are exceeded, or if the vehicle is modified such that it will not comply with applicable emission standards throughout its useful life, the body builder, 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 certain other requirements. 2012 MODEL YEAR VEHICLES ARE EMISSION 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 CERTIFIED TO FEDERAL STANDARDS CAN 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 GUIDANCE CONSULT EPA’S “POLICY ON CROSS BORDER SALES OF CALIFORNIA VEHICLES.” HIGH ALTITUDE REQUIREMENTS United States Environmental Protection Agency regulations for the 2012 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.]. CANADA: IF THE COMPLETED VEHICLE IS INTENDED 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. 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 instructions for incorporating such hardware into the completed vehicle’s electrical or mechanical systems are strictly followed. MEDIUM DUTY PASSENGER VEHICLES (MDPV) The EPA adopted separate emissions standards and requirements for MDPVs beginning in 2005. A MDPV is defined as a heavy-duty vehicle with a GVWR 10,000 lbs. or less 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 certified to MDPV standards and may be converted to MDPVs without requiring additional emission certification. FRONTAL AREA AND WEIGHT RESTRICTIONS: Complete 5.4L and 6.8L Vans and Wagons certified to California >3856 kg [8500 lb] Medium Duty Vehicle (MDV) protocol also have vehicle weight and frontal area restrictions. Modifiers that add weight to a vehicle or increase the frontal area of a 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. Some heavy-duty incomplete vehicles are certified using chassis certification protocol and will require vehicle weight and frontal area restrictions (to retain emission certification). If your 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 certified using heavy-duty engine protocol are not limited by weight and frontal area restriction for exhaust emissions. It is important that the final stage manufacturer observe vehicle restrictions from vehicle safety requirements, etc., which are located elsewhere in this manual. IMPORTANT: For purposes of Government Regulation, a body builder, installer, or any subsequent manufacturer may be considered a manufacturer. E-SERIES (February, 2011) 49 Further, to avoid any question of certification coverage, approval of any modification or use of an engine or vehicle which may alter or render inoperative any of the emission control components must be obtained from the United States Environmental Protection Agency by the manufacturer making such modification 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 modification 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. 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 first conforms to the regulatory definition of “vehicle” to comply with the requirements imposed upon manufacturers by these regulations. EMISSION CERTIFICATION INFORMATION TAMPERING WITH NOISE CONTROLS MALFUNCTION INDICATOR LIGHT (MIL) 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. The “Malfunction Indicator Light” is used to indicate malfunctions of the engine’s emission control system and certain powertrain emissions-related components. For all incomplete vehicles, except Basic (Stripped) Chassis (which is not equipped with an instrument panel), the MIL is Ford-installed and operational in the instrument panel. The E-Series Basic (Stripped) Chassis vehicle has the MIL warning light installed in the instrument cluster, which is shipped in the dunnage box. If an alternate instrument cluster is utilized, the final stage manufacturer must install an operational MIL in the instrument cluster. The MIL must be located on the driver’s-side instrument panel, be of sufficient illumination and location to be readily visible under all lighting conditions and shall be amber in color when illuminated. The MIL, when illuminated, shall display the phrase “Check Engine” or “Service Engine Soon”. The word “Powertrain” may be substituted for “Engine” in the previous phrases. Alternatively, the ISO engine symbol may be substituted for the word “Engine” or for the entire phrase. This is a requirement for emission certification. 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 absorptive material. • Removal of or rendering inoperative the engine speed governor so as to allow engine speed to exceed manufacturer’s specifications. • Removal or modification of air duct, air intake choke or silencer, air cleaner, or air cleaner element. OZONE DEPLETING SUBSTANCE (ODS) • Removal of, or rendering inoperative, exhaust system components including the catalyst inlet pipe, muffler, outlet pipe, resonator, or diffuser. 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 identified with a “clearly and conspicuously attached label.” • 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. Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2012 Ford Truck incomplete vehicles will not have Class I ODS content. Additional noise emissions information is contained in the Ford Truck Body Builders Layout Book. 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 warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. WARRANTY AND MAINTENANCE A copy of the appropriate Ford Truck Owners Guide and Warranty Guide 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. VEHICLE EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Vehicle Emission Control Information (VECI) label must be affixed 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 affixed to any equipment that is easily detached from the vehicle. EVAPORATIVE EMISSIONS All 2012 Federal light and heavy duty trucks and all California vehicles with gasoline engines are required to comply with evaporative emissions requirements established by the Environmental Protection Agency or the California Air Resources Board. Production fuel systems supplied on incomplete 2012 model year trucks manufactured by Ford Motor Company comply with these requirements. If the subsequent stage manufacturer adds to or modifies the fuel system in any manner, it becomes the responsibility of the modifier 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. EMISSION CERTIFICATION INFORMATION When the VECI label is supplied, but not attached to the vehicle, it must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affixed or to be affixed, 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 Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii), as applicable. 50 E-SERIES (February, 2011) CALIFORNIA FUEL VAPOR RECOVERY For the VECI and VIN labels, sufficient clearance shall be provided to use a non-contact bar-code Reading Wand. For the VECI 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 fluids, water, ethylene glycol), under hood temperatures, steam cleaning, and paints or paint solvents. 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 Figures J & K (Ref: Standard 301) will comply with the “Specifications 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 K illustrates a typical point Z). The cylindrical zone uses the axis described above, starts at the outer most surface of the Ford supplied fuel filler housing, and projects outward (away from the frame). The fuel pipe housing component is shown on the referenced figures and is attached to the aftermarket body via 3/16 inch diameter rivets. 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. CALIFORNIA MOTOR VEHICLE EMISSION CONTROL LABEL To meet California emission certification regulations, the Vehicle Emission Control Information (VECI) 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 affixed in such a manner that it cannot be removed without being destroyed or defaced, and shall not be affixed 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 affixed to any equipment which is easily detached from the vehicle. As used in these specifications, 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 flexible parts, (e.g., vacuum hoses, ignition wires). Alternately, information required by these specifications 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 flexible parts that can be moved out of the way without disconnection, obstruct the label. While there are currently no RFI regulations in the United States specifically 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 in the “Canadian Vehicles” section 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 qualified technician. In addition, to ensure continued compliance with the FCC’s regulations, RF devices must not be modified 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.) Completed vehicles for retail sale in California require a machine-readable Vehicle Identification Number (VIN) bar-code label made of paper, plastic, metal, or other permanent material which shall be affixed 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. 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. • Basic (Stripped) Chassis type vehicles: Conformity with CARB Motor Vehicle Emission Control Label specifications for VIN label cannot be determined based upon the components supplied on this incomplete vehicle. Accordingly, Ford Motor Company makes no representation as to conformity with this requirement. E-SERIES (February, 2011) Additional guidance for installing two-way mobile radios can be found via the web at www.fordemc.com/docs/download/ Mobile_Radio_Guide.pdf. 51 EMISSION CERTIFICATION INFORMATION SUPPLEMENTS SUPPLEMENTS 52 E-SERIES (February, 2011) 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. The Ford Truck Body Builders Layout Book can be accessed via the web at www.fleet.ford.com/truckbbas under the “Publications” tab. FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to specific Model Year and vehicle types. Ford Service Publications are available by subscription via the web at www.motorcraft.com. 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 toll free 877-840-4338 or e-mail via the web at www. fleet.ford.com/truckbbas under the “Contact Us” tab. E-SERIES (February, 2011) REFERENCE INFORMATION FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN, MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE, ONTARIO L6J 5E4