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2014 E-Series Incomplete Vehicle Manual (February

1. x X D x x x x Y LJ FRONT OF VEHICLE NOTE SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW DIMENSIONS ARE INCHES FOR THE PURPOSE OF CLARITY FIGURE F1 BODY PANEL WINDOW REMOVAL AREA E SERIES DRIVER SIDE L H STATEMENTS OF CONFORMITY 26 E SERIES February 2013 gt CUTLINE CUTLINE SECTION E SECTION G THE SPOTWELDS X IN lt THIS AREA MUST REMAIN INTACT w Z RE N x DX X X X X X X Xx x x 21 00 MAXIMUM WITH x SLIDING DOOR i 7112 x 28 00 x MAXIMUM Y WITH CARGO DOORS oo o o IG 4 FRONT OF VEHICLE NOTE SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW DIMENSIONS ARE IN INCHES FOR THE PURPOSE OF CLARITY FIGURE F2 BODY PANEL WINDOW REMOVAL AREA E SERIES PASSENGER SIDE E SERIES February 2013 27 STATEMENTS OF CONFORMITY END OF ROOF EXTENDED END OF ROOF OUTER EDGE REGULAR VAN END OF ROOF OF TROUGH CUTAWAY L J
2. B PILLAR REINFORCEMENT i lt 508 WINDSHIELD 2 00 208 2 E HEADER 8 00 8 00 LT TL p S se SECTION AT CUT mae TUI or RooF INE CUT LINE LINE REGULAR VAN EXTENDED VAN OR WAGON HEADLINER PLANE FOR VEHICLES NOT EQUIPPED WITH A FORD HEADLINER USE A PLANE DETERMINED BY A POINT AT THE LOWER REAR OF THE WINDSHIELD HEADER TO THE MIDPOINT ON THE BPILLAR REINFORCEMENT FRONT OF VEHICLE DIMENSIONS ARE INCHES NOTE SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS FIGURE F3 ROOF PANEL REMOVAL AREA E SERIES STATEMENTS OF CONFORMITY 28 E SERIES February 2013 209 209 209 209 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 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 requiremen
3. 40 High Altitude Requirements 40 Emission Control Hardware etii tete nte rir 40 Unleaded Gasoline Label sene 40 Exterior NOISE suu L o ped A RII REI ED uu ass 40 Tampering with Noise Controls 1 aa 41 Warranty and Maint ena ce l uuu e 41 Evaporative EMISSIONS u L uU 41 Malfunction Indicator Light MIL e 41 Ozone Depleting Substance 05 41 Vehicle Emission Control Information Label 41 California Fuel Vapor 42 California Motor Vehicle Emission Control Label 42 Radio Frequency Interference 42 SUPPLEMENTS iei Iun diet 43 44 REFERENCE INFORMATION Inside Back Cover E SERIES February 2013 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 Ambulance is a
4. 101 102 The statement below is applicable to the following incomplete vehicle type E Series Basic Stripped Chassis This vehicle when completed will meet the identification color and illumination requirements of Standard 101 Controls and Displays based upon the components supplied by Ford Motor Company However component location and visibility requirements are the responsibility of the final stage manufacturer accordingly Ford Motor Company makes no representation as to comformity to the component location and visibility requirements of this Standard 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 brake shift 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 E SERIES February 2013 STATEMENTS OF CONFORMITY 102 103 103 104 104 The statements below are applicable to the following incomplete vehicle type E Se
5. CG CG vc Passenger load See E Series Passenger Load Table Vertical distance from the ground to the center of gravity inches of the completed vehicle Horizontal distance from of the front wheels to completed vehicle center of gravity inches Vertical distance from the ground to the center of gravity of the SUB and or permanently attached added equipment inches Vertical distance from the ground to the center of gravity of the chassis inches including cab if original equipment Taken from Table F Horizontal distance from the of the front wheels to the P inches passenger load taken from Table D Weight of the SUB and or permanently attached added equipment pounds Weight at the rear wheels of the SUB and or permanently attached added equipment pounds Weight at the rear wheels of the vehicle chassis and cab fuel tanks full pounds Including option weight Weight of the vehicle chassis and cab fuel tanks full pounds Including option weight z Vehicle wheelbase inches W Total unladen weight W W P GVWR Gross Vehicle Weight Rating of the vehicle W w rl SUB pounds z Remaining cargo capacity pounds Where W GVWR W W P Weight of the remaining cargo capacity on the rear wheels pounds WB Horizontal distance from the of the front wheels to the cargo center of
6. 10 or 11 1 on bottom flange 3 fasteners are 76 2mm 3 00 centers Item 16 50 8mm 2 00 centers FORD PROVIDED 25 4 12 0mm BOLT 6 REQ D 1 00 TORQUE 70Nm 52 LB FT F TYPICAL 268 0 7788 Q 2875 0 161 4 30 66 93 5 MINIMUM _ THE FUEL FILLER HOLE IN ITEM 15 FLOOR MUST BE 3 0 12 LARGER THEN BASE OF ITEM 16 1 2 BOLT WASHERS amp NUT GR5 2438 4 TORQUE 95Nm 70 LB FT 96 00 MAY BE REMOVED TO ACCOMMODATE WHEELHOUSE CLEARANCE 14 0 x 28 0 55 x 1 10 MAX 2 SLOTS IN ITEM 12 13 amp 14 SEE VIEW A FOR BUMPER CORNER BRACE INSTALLATION FORD PROVIDED ISOLATORS 6 DIMENSIONS ARE INCHES FIGURE K1 E SERIES DRW SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE STATEMENTS OF CONFORMITY 36 E SERIES February 2013 E 450 BUMPER CORNER BRACE 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 3 86 CORNERS ON BRACKETS MINIMUM 12 mm 0 5 RADIUS AND NO SHARP EDGES 1051 DIA 4 HOLES BOLT NUT GC 10 9 TORQUE 70 Nm 52 LB FT SEE VIEW C FOR HOLE DIMENSIONS LOCATION 14 0 55 DIA HOLE 985 6 38 80 JTO OF 36 0 DIA HOLE 492 8 36 0 19 40 TO OF SILL 142 DIA 2 HOLES 42 7 1 68 8 0 L
7. 24 IN TO ALL ADJUSTED MAIN VIEW POSITIONS SECTION A NOTE ALL DIMENSIONS ARE IN MILLIMETERS FIGURE A E SERIES FRONT SEAT RESTRAINT SYSTEM STATEMENTS OF CONFORMITY 22 VIEW A VIEWB 3 V NOTE 1 NO OMISSION OR SUBSTITUTION vewa remain clear of all trim panels gere SEQUENCE VIEW OF FRONT SEAT LAP AND SHOULDER SAFETY BELTS USED WITH SZ NOTE2 TORQUE CONTROL ALL TORQUE BUCKET SEAT OR CAPTAINS CHAIR DRIVER S SIDE REQUIREMENT MUST BE MAINTAINED ALL WAGON VAN MODELS ONLY NOTE Optional Cutaway B Pillar SECURELY SEATED trim package utilizes Van model V NOTE3 AVOID CONTAMINATION V NOTE 4 ASSURE THAT SEAT BELT WEBBING seat belt system IS NOT TWISTED AT INSTALLATION WV NOTE 5 FRONT SPIKE TEST 072021 REAR SPIKE TEST QT3004 OR VSR BENCH TEST QT2100 INTERIOR TRIM 9 5 RADIUS MIN 37 IN RETRACTOR 12 5 MIN UP 4 50 IN ADJUSTED Lif OVERLAP 6 0 amp 124 IN POSITION Tf 3 0 12 IN UP POSITION VIEW IN CIRCLE C 6 0 MIN CLEARANCE 24 IN AROUND BELT i PERIPHERY AT MAX TRAVEL POSITIONS lt 6 0 MIN M sear BELT m 24 IN E WEBBING 4 6 0 MIN 24 IN SECTION B DIMENSIONS ft Ib OR INCHES E SERIES February 2013 SEAT ASY BUCKLE ASY 15610E15 PIA BOLT TORQUE 40 0 6 0 Nm 29 5 4 ft lb V N801078 SCREW M amp x 1 25 HEX 4 REQ D TORQUE 25 0 3 8 Nm 18 4 2 8 ft lb 156170
8. 7900 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 Minimum unloaded vehicle weight for Cutaways completed as school buses is defined in Standard 105 requirements TABLE B TABLE C MINIMUM SUB WEIGHT CG Horizontal distance from front axle to cargo CG Kilogram Model WB in in Model Pound Regular Van 138 116 E 350 Cutaway SRW 381 TExtended Van or Extended Wagon 138 126 3505mm 138 in WB 840 Cutaway SRW 138 121 E 350 Cutaway DRW 204 DRW 138 127 3505mm 138 in WB 450 Comm Cab Box Partition 158 134 4013mm 158 in WB 525 t Comm No Partition DRW 158 143 E 350 Cutaway DRW 238 DRW 176 153 4470mm 176 in WB 525 Comm DRW 176 160 E 450 Cutaway DRW 238 1 4013 158 in WB 525 If CG is not given in the table or if the location of your cargo is not in the normal cargo area then your CGhl may be estimated E 450 Cutaway DRW 298 as the distance from the of the front wheel to the horizontal 4470mm 176 in WB 525 midpoint of the cargo area E 350 Basic Stripped Chassis DRW 862 All WB 1900 E 450 Basic Stripped Chassis DRW 998 All WB 2200 TABLE D CG Horizontal distance from fro
9. Bus Window Retention and Release X X 219 Windshield Zone Intrusion X 2 X 2 X 2 X 2 U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS E SERIES February 2013 U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS Application By Vehicle Type Continued from Inside Front Cover Vehicle Type Bus Not Truck Truck Standard School School Not Walk in Equipment Number Title of Standard Bus Bus Walk In Van MPV Van 1 220 School Bus Rollover Protection X 221 School Bus Body Joint Strength X 222 School Bus Passenger Seating and Crash Protection X 225 Child Restraint Anchorage Systems U S only X 6 X 6 X 6 X 6 301 Fuel System Integrity X X 2 X 2 X 2 301 1 LPG Fuel System Integrity Canada only X X 301 2 CNG Fuel System Integrity Canada only X X 302 Flammability of Interior Materials X X X X 303 Fuel System Integrity of Compressed Natural Gas Vehicles U S only X 2 X 2 X 2 X 2 X 2 304 Compressed Natural Gas Fuel Container Integrity U S only x x x x 305 Electric Powered Vehicles Electrolyte Spillage and Electrical Shock Protection X X X X X 403 Platform Lift Systems for Motor Vehicles X 404 Platform Lift Installations in Motor Vehicles X X X X PART Parts and Accessories Necessary for Safe 393 67 Operation Liquid Fuel Tanks X X PART Vehicle Identification Number VIN Requirements X X X X 565 U S only 1106 Noise Emissions Canada
10. SIDE 9 099 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 NOTES FACE OF FILLER PIPE SUPPORT TO BE INSTALLED ON BODY IN VERTICAL PLANE 7 TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 2 9 4 3 Nm 25 38 in Ib DIMENSIONS ARE INCHES A FUEL SYSTEM FILLER HEIGHT SCHOOL BUS 395 15 6 MINIMUM OTHER 319 12 6 MINIMUM CRITICAL CONTROL ITEM HOSES SO NO LOW SPOTS OCCUR GROUND STRAP FUEL TANK FIGURE J E 350 450 CUTAWAY AND BASIC STRIPPED CHASSIS FUEL FILLER PIPE INSTALLATION FOR AFT OF AXLE FUEL TANK E SERIES February 2013 STATEMENTS OF CONFORMITY ITEM PART NAME MATERIAL QUANTITY 1 SUPPORT BODY ISOLATOR TO CROSS SILL L H 6 35mm 0 25 HRLC STEEL 1 2 SUPPORT BODY ISOLATOR TO CROSS SILL RH 6 35mm 0 25 HRLC STEEL 1 3 BRACKET SPACER FOR ISOLATOR SUPPORT 6 35mm 0 25 HRLC STEEL 2 TO FRONT CROSS SILL 4 BRACKET SPACER FOR ISOLATOR SUPPORT 6 35mm 0 25 HRLC STEEL 2 TO SECOND CROSS SILL 5 SILL FRONT CROSS 1 9mm 0 075 14 GA HRLC STEEL 1 6 SILL SECOND CROSS 1 9mm 0 075 14 GA HRLC STEEL 1 7 SILL THIRD amp FOURTH CROSS 1 9mm 0 075 14 GA HRLC STEEL 2 8 GUSSET CROSS
11. access from the driver s area to the back of the vehicle ch ssis tronqu 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 d sign e Final Stage Manufacturer a pe
12. 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 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 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 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 l
13. below is applicable to the following incomplete vehicle type if the GVWR is 4536 kg 10 000 Ibs 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 The statements below are applicable to the following incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less Incomplete E Series Van or Wagon 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 The statement below is applicable to the following incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less Incomplete E Series Van with no front seats 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 The state
14. gravity inches taken from Table C For many common vehicles the 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 W 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 CG OF CHASSIS CG OF COMPLETED VEHICLE i CG OF SUB SUB E WB CG hl gt CGh gt lt CG np m gt GVWR Wrb Wb Wre WI STATEMENTS OF CONFORMITY 12 E SERIES February 2013 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 Ib GVWR Wheelbase Millimeter Maximum Model inch Unloaded Vehicle Weights Kilogram pound E 150 Regular and Extended Van 3505 138 3130 6900 E 150 Regular Wagon 3505 138 3130 6900 E 250 Regular and Extended Van 3505 138 3130 6900 E 350 Regular and Extended Van 3505 138 3583 7900 E 350 Regular and Extended Wagon 3505 138 3583
15. heat or weld splatter All non metallic components must be removed The statements below are applicable to the following incomplete vehicle types if the vehicle GVWR is 4536 kg 10 000 Ib 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 Il 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 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 1 The completed vehicle s Unloaded Vehicle Weight does not exceed the value designated in Table A corr
16. 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 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 U S Requirements The statement below is applicable to all incomplete vehicles with a GVWR of 4536 kg 10 000 Ibs 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 TIRE AND LOAD INFORMATION SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION T The combined weight of occupants and cargo should never exceed XXX kg or SEATING CAPACITY TOTAL 5 FRONT 2 COLD TIRE INFLATION PRESSURE P195 70R14 FRONT 200 29PSI REAR Pi95 70R14 REAR 200 29PSI COMPACT TIRE SIZE COLD TIRE INFLATION PRESSURE 7125770015 REAR 3 ORIGINAL TIRE SIZE 111 111 111 The statements below are applicable to the following incomplete vehicle types when equipped with a driver seat including untrimmed seat and a c
17. 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 NOTE Ford Motor Company provides Type and Type II FMVSS CMVSS 105 compliance statements for vehicles built to factory standard or optional specifications Suspension ride height and or spring rate modifications are factors that may affect compliance to this Standard If an alterer or final stage manufacturer modifies the suspension ride height or spring rate of the factory equipped vehicle then they are responsible for engineering analysis or physical testing to ensure compliance and sign off to Standard 105 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 Weight Kilogram Pound E 350 SRW 1 2540 5600 E 350 DRW 3030 6680 E 450 DRW 3821 8425 SRW Single Rear Wheels DRW Dual Rear Wheels 1 Aft of axle fuel tank Continued Next Page E SERIES February 2013 105 Continued 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 v
18. necessary for the operation of the vehicle filled to their maximum capacity but without cargo or occupants poids du v hicule 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 acc s en position debout E SERIES February 2013 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 inc
19. of more than 4536 kg 10 000 Ib Incomplete E Series Van or Wagon 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 STATEMENTS OF CONFORMITY 38 E SERIES February 2013 CANADIAN VEHICLES Vehicles to be completed for sale or use in Canada VEHICLE IDENTIFICATION 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 DAYTIME RUNNING LAMP DRL 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 The
20. 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 EMISSION CERTIFICATION INFORMATION 40 IMPORTANT It is the responsibility of the body builder installer or subsequent stage manufacturer to ensure that the maximum completed vehicle curb weight and frontal area specified by Ford Motor Company 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 HIGH ALTITUDE REQUIREMENTS United States Environmental Protection Agency regulations do not contain unique emission certification requirements for trucks that will be sold or delivered to customers for principal use above 1 219 m 4 000 ft EMISSION CONTROL HARDWARE Any body builder installer or subsequent stage manufacturer must also assure that all emission control hardware furnished with incomplete vehicles is on th
21. 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 Removal of or rendering inoperative exhaust system components including the catalyst inlet pipe muffler outlet pipe resonator or diffuser Removal of the fan shroud Removal of or rendering inoperative the fan clutch New vehicles manufactured for sale in Canada must comply with applicable provisions of Canada Motor Vehicle Safety Standard 1106 Noise Additional noise emissions information is contained in the Ford Truck Body Builders Layout Book WARRANTY AND MAINTENANCE A copy of the appropriate Ford Truck Owners Guide and Warranty 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 Ib noise emissions warranty information instructions for maintenance use and repair of vehicle noise emission control systems a maintenance record format and list of prohibited tampering acts EVAPORATIVE EMISSIONS All 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 Age
22. 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 E SERIES February 2013 STATEMENTS OF CONFORMITY 210 2 Canadian Requirements 212 219 212 219 212 219 The statement below is applicable to buses with a GVWR of 4536 kg 10 000 Ib 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 Note 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 INFORMATION Refer to the Design Recommendations section in the Ford Truck Body Builders Layout Book for Second Unit Body Attachment information to aid in designing seco
23. 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 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 7 The completed vehicle s Unloaded Vehicle Weight does not exceed the value designated in Table A corresponding to the model and wheelbase STATEMENTS OF CONFORMITY 32 E SERIES February 2013 OUTBOARD FRAME REINFORCEMENT SRW ONLY NO MODIFICATIONS NO ATTACHMENTS LOWER 2 AND UPPER 1 FRAME FLANGE REINFORCEMENTS SRW amp DRW BACK TO BACK CROSSMEMBERS SRW ONLY REQUIRED FRAME HOLES E 350 ONLY REFER TO FIGURE H1 FOR DETAILS REQUIRED CROSSMEMBER SRW ONLY TUBULAR STYLE LOWER C M REQUIRED CROSSMEMBERS E 350 138 SRW CUTAWAY W SCHOOL BUS PREP PACKAGE FIGURE G2 E 350 CUTAWAY REQUIRED REAR CROSSMEMBER FOR SRW SCHOOL BUS PREPARATION PACKAGE 301 The statements below are applicable to the over 4536 kg 10 000 Ib GVWR E 350 DRW and E 450 Cutaway when equipped with School Bus Prep Package and comple
24. this manual belongs The label identifies the following information which pertains only to the vehicle with the corresponding VIN The GVWR The front and rear GAWRs Tire and wheel size 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 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 chart California Air Resources Board CARB requires a Vehicle Identification Number VIN Label having a non contact bar code reading wand capability The bar code directly below the VIN on the Incomplete Vehicle Information Label when provided will comply with this regulation The Canadian Motor Vehicle Safety Act and Regulations require installation of an Incomplete Vehicle Information Label with the National
25. 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 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 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 Nochanges 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 207 Continued Next Page TABL
26. 1 FRT ST PIA TO BUCKLE 756912 TAPPING WIRING ASYSEAT CONTROL FEED JUMPER NUT amp WASHER ASY 2 REQ TORQUE 55 0 8 3Nm 14A701 40 6 6 ft lb SWITCH ASY ST CONTROL 1560094 DL M SUPPORT ASY S7N620481 SCREW 2 REQ D V 611D02A STUD COVER 4 REQ D 40 6 6 ft lb POWER L H SHOWN 18 4 2 8 ft lb E SERIES DRIVER L H SEAT INSTALLATION POWER TRACK ASY SCREW 4 2 x 19 NUT M8 x 1 75 HEX FLANGE TORQUE 55 083 Nm TORQUE 250 3 8 Nm V SEAT ASY N801078 SCREW M8x1 25 HEX 4 TORQUE 25 0 3 8 Nm 18 4 2 8 ft lb 15618B47 TRACK ASY Y 15618846 THAGKASY BUCKLE ASY 15610E 1561755 PIA BOLT TORQUE HANDLE FRT ST 40 0 6 0 Nm TRACK 7 29 5 4 14A699 j WIRE ASY amp COVER FRT ST PIVOT 212 1 Z 1 56912 V 1562506 2 t SCREW 4 2 x 19 0 SUPPORT ASY 9 4 TABPEING R H MNL j CHILD SEAT N 611D02A TETHER SLOTS eee N620432 M10 S7N811326 NUTWAWASHER N802853 SCREW 2 REQ d BEOD STUD 2 REQ D TORQUE 55 0 8 3 Nm 40 6 6 ft Ib MANUAL R H SHOWN E SERIES PASSENGER R H SEAT INSTALLATION PIA BOLT TORQUE 40 0 6 0 Nm 29 5 4 ft lb 579988 CLEARANCE 7 ZONE o DR 15610E14 T CLEARANCE PASS 15610E15 15 10 ZONE BUCKLE ASY FOR SHIPPING s Mg PURPOSES ONLY 1 Nec ONLY 4 SCREWS NO COVER FRT NU
27. 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 302 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 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 302 303 304 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 U S Requirements The statement below is applicable to a
28. 4 J E FORWARD MOST A v 7 OUTBOARD FRONT PASSENGER 2 POINT A SEAT POSITION IS 20 mm 0 78 IN FORWARD SEAT POSITION IS AT THE MIDPOINT OF REARMOST POSITION OF AVAILABLE TRAVEL A B D E F MIN MAX DRIVER SEAT VAN AND CUTAWAY 217 8 113 0 385 3 356 0 67 0 937 4 8 57 4 45 15 17 14 01 2 64 36 90 PASSENGER SEAT VAN AND CUTAWAY 269 1 113 0 377 3 412 0 65 0 960 1 10 59 4 45 14 85 16 22 2 56 37 80 THE TORSO ANGLE IS DETERMINED BY USING THE METHOD SPECIFIEDIN SAE J826 JULY 1995 mE oursip P d lt pa TORSO ANGLE POINT A A rft FRONT NN IC FASTENER pj UN DRIVER SIDE ONLY SEAT BACK PIVOT 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 STATEMENTS OF CONFORMITY 24 E SERIES February 2013 RESTRAINT CONTROL MODULE UNDER DRIVER S SEAT STEERING WHEEL PANEL ENT PANEL HARNESS DRIVER AIRBAG PASSENGER AIRBAG READINESS INDICATOR RESTRAINTS CONTROL MODULE ON FLOOR UNDER DRIVER SEAT AT SAFETY WALL ENGINE COMPARTMENT HARNESS DO
29. 49 2 0 31 1 94 13 0 0 51 DIA 8 HOLES VIEW B RELIEF TO PROVIDE MINIMUM 12 mm 0 50 CLEARANCE TO FILLER PIPE 1303 1 _ LL 81 30 102 0 4 02 ITEM 3 amp 4 ARE WELDED TO ITEM 1 OR 2 ON ALL 4 EDGES SUPPORT BODY ISOLATOR TO CROSS SILL L H SHOWN R H SYMETRICALLY OPPOSITE EXCEPT FOR RELIEF FRONT OF VEHICLE TOP VIEW OF FRAME amp BUMPER i 1 2 BOLTS WASHERS amp NUTS GR5 Gl TORQUE 95Nm 70 LB FT 134 0 5 28 128 438 8 110 0 4 33 15 46 677 CORNERS ON BRACKETS MINIMUM 12 mm 0 5 RADIUS AND NO SHARP EDGES 1180 DIA 4 HOLES M12 BOLT amp NUT GC 10 9 TORQUE 70 Nm 52 LB FT SUPPORT CROSS SILL OUTER L H SHOWN R H SYMETRICALLY OPPOSITE TRIM WITH 45 ANGLE TO REMOVE SHARP CORNER 5717 22 51 23 1 0 91 WELD SHEET METAL RELIEF AFTER FORMING 104 8 4 18 GUSSET CROSS SILL TO OUTER SUPPORT R H SHOWN L H SYMETRICALLY OPPOSITE DIMENSIONS ARE INCHES E SERIES February 2013 37 FIGURE K2 E SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE OVER 4536 KG 10 000 LB GVWR STATEMENTS OF CONFORMITY 305 403 404 Part 393 67 Part 565 Part 565 The statement below is applicable to all incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less This incomplete vehicle does not com
30. DO NOT DESTROY THIS MANUAL IS REQUIRED BY LAW KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER 2014 E SERIES INCOMPLETE VEHICLE MANUAL Incomplete Vehicle Types For This Manual INCOMPLETE WAGONS E SERIES E CUTAWAY e N E SERIES d BASIC s CHASSIS N February 2013 VEC24 19A268 AA U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS Application By Vehicle Type Vehicle Type Bus Not Truck Truck Standard School School Not Walk in Equipment Number Title of Standard Bus Bus Walk In Van MPV Van 1 101 Control Location Identification and Illumination X X X X X 102 Transmission Shift Lever Sequence Starter Interlock amp Transmission Braking Effect X X X X X 1038 Windshield Defrosting amp Defogging Systems X X X X X 104 Windshield Wiping and Washing Systems X X X X X 105 Hydraulic and Electric Brake Systems X X X X X 106 Brake Hoses X X X X X X 108 Lamps Reflective Devices amp Associated Equipment X X X X x x 108 1 Headlamps Canada only x x x x x x 110 Tire Selection and Rims U S only X 2 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 X 118 Power Operated Window Partition and Ro
31. DRL circuits in the Smart Power Distribution Junction Box SPDJB are not to be altered The SPDJB module is not to be repositioned 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 CANADIAN RADIO FREQUENCY INTERFERENCE RFI INFORMATION All vehicles powered by spark ignition engines e g gasoline natural gas or propane engines and manufactured in Canada or for sale or use in Canada are subject to the Canadian Regulations for the Control of Interference to Radio Reception per Interference Causing Equipment Standard ICES 002 and applicable test method according to CAN CSA C108 4 MO6 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 The following information is supplied to subsequent stage manufacturers to help them avoid increasing the RFI
32. E H E SERIES COMPLETED UNTRIMMED SEAT WEIGHT Maximum Weight Ib Description Driver Side Passenger Side E Series Captain s Chair Manual Tracks 59 0 61 0 E Series Captain s Chair Manual Tracks Manual Lumbar 62 0 68 0 E Series Captain s Chair Power Tracks Manual Lumbar 68 0 N A E SERIES February 2013 19 STATEMENTS OF CONFORMITY 207 Continued 207 208 208 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 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 pretension
33. Electrical Wiring Section of the Ford Truck Body Builders Layout Book STATEMENTS OF CONFORMITY 14 TABLE G Standard 108 Lighting Equipment E Series Completed as Truck MPV Bus or School Bus c ES TEE qo c ET S0 So Headlamps S S Tail Lamps S R S R Stop Lamps S R S R Center High Mounted Stop Lamp CHMSL R N License Plate Lamps S R S R Reflex Reflectors Side Front S S Side Rear R R Rear R R Side Marker Lamps Front s S Rear R R Back Up Lamps S R S R Turn Signal Lamps Front Rear S R S R Turn Signal Operating Unit Turn Signal Flasher 2 S S Vehicular Hazard Warning Signal Operating Unit S S Vehicular Hazard Warning Signal Flasher S S Identification Lamps Front N R Rear N R Clearance Lamps Front N R 1 Rear N R Parking Lamps R N School Bus Lamps and Switches R R School Bus except Multifunction School Activity Bus S R N 1 2 Required on completed vehicle and supplied with the incomplete vehicle van and wagon Required on completed vehicle and not supplied with the incomplete vehicle cutaway and stripped chassis Not required for completed vehicle 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 Turn
34. 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 See combined statements under 212 219 for all vehicle types 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 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
35. 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 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 207 207 Builders Layout Book for Seat and Lap amp Shoulder Belt System information that is in addition to the statements which follow 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
36. LUMINUM BUMPER 203 mm 4 7 mm 0 2 in 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 Ib 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 4 plate reinforcements doublers using 1 9 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 76 3 0 in apart or 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 34 E SERIES February 2013 301 1 The statement below is applicable to all incomplete vehicle types This incomplete vehicle does not comply with CMVSS Standard
37. NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS el aaa MUST BE METALTO METAL THAT ARE IDENTIFIED IN THIS ILLUSTRATION FIGURE E SERIES SUPPLEMENTAL RESTRAINT FIGURE E2 E SERIES RESTRAINT CONTROL MODULE SYSTEM Air Bags Sensors and Wiring Sensor system also connected to pyrotechnic buckle pretensioners not shown which are assembled to the front seat pedestals Passenger air bag and buckle pretensioner replaced by cover delete resistor and bracket delete resistor respectively on vehicles that have an option that deletes the front passenger restraint system W707935 SCREW 14B321 SNS amp BRKT TORQUE 12 0 1 8 Nm 9 1 3 ft lb ASY A BAG FRT 14405 WIR ASY RR LP REF FRONT rT FLOOR PAN FRONT OF VEHICLE a FIGURE E3 E SERIES RESTRAINT CONTROL MODULE E SERIES February 2013 25 STATEMENTS OF CONFORMITY CUT LINE ra CUT LINE CUT LINE SECTION C SECTION B CUT LINE MN DA X M CUT LINE SECTION A SECTION D 7112 7112 28 00 1 28 00 MAXIMUM MAXIMUM THE SPOTWELDS X IN THIS AREA MUST REMAIN INTACT gt B SO NN MX SUN IT x
38. O FRONT V 15611B09 BELT AND RETRACTOR ASSEMBLY OF VEHICLE SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE CUT AWAY MODELS ONLY PIA BOLT TORQUE TO 47 5 7 2 NOTE 1 2 PANEL ASSEMBLY COVER SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE PIA BOLT V TORQUE TO 47 5 7 2 Nm V NOTE 1 2 CAUTION Components installed near trim panels adjacent to restraint system components must 15602B90 COVER ASSEMBLY CUT AWAY AND VAN MODELS CLOSE D RING COVER AFTER INSTALLATION OF BELT ASSEMBLY W520113 V TORQUE TO 40 0 6 0 N m NOTE 1 2 15611B08 BELT AND RETRACTOR ASSEMBLY V PIA BOLT TORQUE 47 5 7 2 V NOTE 1 2 CUT AWAY PANEL ASSEMBLY COVER 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 V THIS SYMBOL MEANS USE ONLY THE PART INDICATED DO NOT SUBSTITUTE 22 6 5 MIN FROM 25 IN RELEASE KNOB 2 27 gt TO INTERIOR TRIM S 13 0 MIN FROM SECTION D 50 IN ADJUSTED LES COVER TO POSITION UD N RELEASE KNOB n d S 2 0 MIN 08 IN 8 FULL N WITH DRING THREAD LOCATED ON MN EXPOSED SHLDR BOLT AY ff T 1560262 REF A B 7 P 2 FRONT OF VEHICLE 6 0 MIN CLEARANCE D
39. PMS is subject to interference from added equipment or devices that emit radio frequency RF energy 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 SPDJB if equipped Body Control Module BCM if equipped Radio Frequency Receiver RFR if equipped Tire Pressure Module TPM if equipped 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 manufacture the function of the Tire Pressure Monitoring System is verified to be in accordance with FMVSS 138 and in accordance with information provided in the vehicle s Owner Guide 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 STATEMENTS OF CONFORMITY 201 201 The statements below are applicable to incomplete vehicles with a GVWR of 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standa
40. PV 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 Ibs 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 23856 kg 8500 Ib 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
41. SILL TO OUTER SUPPORT L H 1 9mm 0 075 14 GA HRLC STEEL 4 9 GUSSET CROSS SILL TO OUTER SUPPORT 1 9mm 0 075 14 GA HRLC STEEL 4 10 SUPPORT CROSS SILL OUTER LH 3 0mm 0 120 11 GA HRLC STEEL 1 11 SUPPORT CROSS SILL OUTER R H 3 0mm 0 120 11 GA HRLC STEEL 1 12 BUMPER REAR 4 7mm 0 187 HRLC STEEL 1 13 BRACKET BUMPER TO FRAME L H 6 35mm 0 25 HRLC STEEL 1 14 BRACKET BUMPER TO FRAME RH 6 35mm 0 25 HRLC STEEL 1 15 FLOOR 1 9mm 0 075 14 GA HRLC STEEL 1 16 HOUSING FUEL FILL NECK 1 9mm 0 075 14 GA HRLC STEEL 1 17 CORNER BRACE BUMPER TO FRAME 5 3mm 0 21 5 GA HRLC STEEL 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 Ib and tensile strength of 2000 Ib or equivalent weld Each fastener will require a 6 91 272 to 6 63 261 dia hole PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING LOCATION Item 5 to 15 48 estimated 101 6mm 4 00 centers on front and rear flange Item 6 to 15 48 estimated 50 8mm 2 00 stagger on front and rear flange Item 7 to Item 15 47 estimated 50 8mm 2 00 centers Item 5 to Items 8 or 9 6 101 6mm 4 00 centers Item 6 to Items 8 or 9 6 101 6mm 4 00 centers staggered top to bottom of cross sill Item 7 to Items 8 or 9 6 101 6mm 4 00 centers staggered top to bottom of cross sill Items 8 or 9 to Items 10 or 11 3 on vertical side of item
42. Safety mark on it on vehicles manufactured for sale in Canada A sample of a typical label is shown below OPTIONAL PREP PACKAGES 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 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 MANUPACTURE MET Un x6 0K Hy AE Od a TYPE TE ON PAGE 8 _ AMBULANCE PREP PKG OPTIONAL _ BINE RC 87 050 PREP PACKAGE vso 1 8 Wr Y05 VEHICLE ULN v 5054 3520472 M TYPICAL E SERIES U S DATE OF MANUFACTURE VEHICLE TYPE SEE CHART ON PAGE 8 OPTIONAL ___ Equipped with the Ford Ambulance Pr I PREP PACKAGE T RC y EN COMPLIES ICES NMB 002 6E410 1019 158 AE 1 E 05 50 VEHICLE MADE IN U S A uu gt SU5A 3520472 AA TYPICAL E SERIES CANADA INCOMPLE
43. TE VEHICLE INFORMATION LABELS E SERIES February 2013 VEHICLE DESCRIPTION COMPLETED VEHICLE TYPES COMPLETED VEHICLES lt 8 939 5TH 6TH 7TH INCOMPLETE VEHICLES gt z m VIN DIGIT 2 5 2 O O 104 0 O lt x 2 25 4295 5 59 F gt lt 00 lt m E Series E1B Incomplete E 150 Wagon X 6 E1E Incomplete E 150 Regular Van X 5 E2E Incomplete E 250 Regular Van X 5 E3B Incomplete E 350 Super Duty Wagon X 6 6 ESE Incomplete E 350 Super Duty Regular Van X 5 1 7 E3F E 350 Super Duty Cutaway X 3 1 4 2 E3K E 350 Super Duty Basic Stripped Chassis X E4F E 450 Super Duty Cutaway X 3 1 4 2 4 E 450 Super Duty Basic Stripped Chassis X S1E Incomplete E 150 Extended Van X 5 S2E Incomplete E 250 Extended Van X 5 S3B Incomplete E 350 Super Duty Extended Wagon X 6 6 S3E Incomplete E 350 Super Duty Extended Van X 5 1 5 7 1 Ambulance Prep Package IMPORTANT 2 School Bus Prep Package 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 3 Motorhome Prep Package 4 Shuttle Bus Prep Package 5 Recreational Van 6 Center Aisle Se
44. TS amp BOLTS ST PVT 611002 STUD COVER DR 1561704 R H TRACK 4 REQ D J N800937 Eu d He SIDE VIEW REAR VIEW j 55 0 8 3 Nm VIEW A FRONT OF VEHICLE zi um CENTER OF VEHICLE w705944 SCREW 2 REQ D 55 0 8 3 Nm 40 6 6 ft lb 14A699 WIRE ASY 1560094 A MANUAL 1561755 DP SUPPORT ASY HDL FRT ST TRK E SERIES DRIVER L H SEAT DELETE OPTION 40 6 6 ft lb DR 1561705 L H TRACK N011488 STUD 2 REQ D FIGURE B E SERIES FRONT SEAT INSTALLATION PRETENSIONER CLEARANCE ZONE 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 1 DIMENSIONS ft lb OR INCHES E SERIES February 2013 23 STATEMENTS OF CONFORMITY SRP INFORMATION PASSENGER SEAT VEHICLE IMPORTANT THE DIMENSIONS IN THIS FIGURE REQUIRE DRIVER SEAT 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 Nal lug ul la ES
45. abel 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 RADIO FREQUENCY INTERFERENCE The ignition system on your vehicle if other than a Basic Stripped Chassis has been designed to be capable of compliance with RFI requirements established by the Canadian government However because Ford Motor Company has no control over how an incomplete vehicle is completed by subsequent stage manufacturers Ford Motor Company does not represent that the completed vehicle incorporating the Ford built components will comply with those requirements Any ignition system component i e spark plugs ignition wiring coil suppressor assembly etc that is replaced should be replaced by the same Ford Motor Company part number or equivalent to maintain RFI suppression While there are currently no RFI regulations in the United States 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
46. ake hose assemblies are added 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 Retlective Devices and Associated Equipment are applicable to allincomplete 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 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 stat
47. 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 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 accordingly Ford Motor Company makes no representation as to conformity with this Standard 210 1 Canadian Requirements The statement below is applicable to buses with a GVWR of 4536 kg 10 000 Ib 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
48. anufactured 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 E SERIES February 2013 TAMPERING WITH NOISE CONTROLS Federal law prohibits the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into such vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use Federal Law also prohibits the use of such vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Removal of fender apron absorbers fender apron barriers underbody noise shields or acoustical absorptive material Removal of or rendering inoperative
49. at Prep Package 7 Aerial Bucket Prep Package E SERIES February 2013 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 101 101 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 a
50. corner of the Incomplete Vehicle Information Label which is affixed to the driver door lock pillar See the sample labels on the following page The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles These vehicles are identified in the Completed Vehicle Types chart Other VSO vehicles may require additional Statements of Conformity which would be included in a Supplement Section of this manual 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 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 E SERIES February 2013 VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER 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
51. dentification Number mounted on the top of the instrument panel 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 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 1106 1106 Canadian Requirements The statements below are applicable to the following incomplete vehicle types with GVW ratings of 4536 kg 10 000 Ib or less Incomplete E Series Van or Wagon 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 Canadian Requirements The statements below are applicable to the following incomplete vehicle types with GVW ratings
52. e 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 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 NOTE Crossmember Installation 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 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 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 moun
53. e effects or damage if this equipment is used Additional guidance for installing two way mobile radios can be found via the web at www fordemc com docs download Mobile Radio Guide pdf EMISSION CERTIFICATION INFORMATION 42 E SERIES February 2013 SUPPLEMENTS E SERIES February 2013 43 SUPPLEMENTS SUPPLEMENTS SUPPLEMENTS 44 E SERIES February 2013 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 amp Vacuum Trouble Shooting Manual Ford Wiring Diagram FORD TRUCK BODY BUILDER ADVISORY SERVICE The Ford Truck Body Builder Advisory Service may be consulted regarding informa tion contained in thi
54. e 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 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 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 The statement below is applicable to the following incomplete vehicle type E Series Basic Stripped Chassis Conformity with S
55. e vehicle and is operational and that applicable instructions for incorporating such hardware into the completed vehicle s electrical or mechanical Systems are strictly followed 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 Ib include a partially or wholly enclosed operator s compartment and are m
56. ed the defined cut out areas shown in Figure F1 F2 and F3 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 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 STATEMENTS OF CONFORMITY 30 E SERIES February 2013 217 219 220 221 222 225 301 Canadian Requirements The preceding statements for FMVSS 217 are appropriate compliance representations for CMVSS 217 Bus
57. ed vehicle 49CFR567 3 DEFINITIONS E SERIES February 2013 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 v hicule 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 e
58. ehicle 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 CENTER OF GRAVITY FOR E SERIES CUTAWAY COMPLETED AS A SCHOOL BUS E 350 E 350 E 450 Location SRW DRW DRW mm mm mm in Vertical Maximum 1 302 0 11 9 Horizontal Maximum 2 2159 0 2718 0 85 0 107 0 Horizontal Minimum 2 1651 0 65 0 1 Measured from top of frame ata point midway between the centerlines of the front and rear axles 2 Measured rearward from the centerline of the front axle 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 p
59. ement 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
60. 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 E SERIES February 2013 39 More specifically All components required to suppress emissions which are removed during service repair or completion of the vehicle must be reinstalled in the manner in which they were installed by Ford Motor Company Shields on ignition coils must remain installed Replacement spark plugs ignition wires and ignition coils must be equivalent in their suppression properties to original equipment Electrical grounds on all components must be retained Metallic components installed on the body or chassis must be grounded to the chassis Electrical circuits added to the vehicle must not be installed near the high voltage ignition components Only static conductive accessory drive belts should be used Fan water pump power steering and other belts should be of the OEM type or equivalent that will not build up a static electrical charge Engine compartment wiring must not be rerouted in any manner The Powertrain Control Module PCM must not be relocated from the posit
61. er 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 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 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 Ib or the Unloaded Vehicle Weight when completed is over 2495 kg 5500 Ib 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
62. erforming 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 crawler mounted 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
63. esponding to the incomplete vehicle s model and wheelbase Continued Next Page STATEMENTS OF CONFORMITY 301 301 Continued 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 The statements below are applicable to the following incomplete vehicle types 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 th
64. f Standard 212 or Standard 219 The completed vehicle s Unloaded Vehicle Weight does not exceed the value designated in Table A corresponding to the vehicle s model and wheelbase t 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 219 213 214 217 217 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 Ib 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 exce
65. hicles with a GVWR of 4536 kg 10 000 Ibs or less 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 bulkheads dividers etc these components will have to conform to the requirements of Standard 201 Section 6 where applicable STATEMENTS OF CONFORMITY 18 201U U S Requirements Section S6 Upper Interior 202a 202a 203 203 204 204 Components The statement
66. 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 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 amp iii as applicable E SERIES February 2013 41 EMISSION CERTIFICATION INFORMATION CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fill pipe Fuel filler pipes installed per Figures J amp 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 p
67. ion as installed by Ford Motor Company Additional guidance for installing two way mobile radios can be found via the web at www fordemc com docs download Mobile Radio Guide pdf STATEMENTS OF CONFORMITY EMISSION CERTIFICATION INFORMATION CAUTION U S 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 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 MEDIUM DUTY PASSENGER VEHICLES MD
68. ion 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 pe
69. justments 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 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 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 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 o
70. lectrical 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 low speed vehicle a passenger car a three wheeled vehicle a truck or a vehicle imported temporarily for special purposes v hicule de tourisme 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 Estab
71. lishes 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 9 15 the reference point employed to position the two dimensional drafting template described in SAE J826 May 1987 abbreviated by Ford Motor Company Seating Reference Point Canada the unique Design H point 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 r f rence de position assise Second Unit Body SUB consists of the body structure and or all the cargo carrying work p
72. loaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of FMVSS 301 Fuel System Integrity Completed vehicles manufactured by Ford Motor Company that are tested to demonstrate compliance with Standard 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 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 Ib or less or equipped with School Bus Prep Package and completed as a school bus f 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
73. ment below is applicable to all incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib 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 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 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 The statements below are applicable to all incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less and the Unloaded Vehicle Weight when completed is 2495 kg 5 500 Ib or less This vehicle when completed will conform to Standard 204 Steering Control Rearward Displacement if E SERIES February 2013 205 205 206 206 No components are added which could influence the rearward displacement of the steering column The steering column steering intermediate and coupling shaf
74. n of the representations for a particular safety standard Compliance statements provided in this manual are of the three following types 49CFR568 4 A statement that the vehicle when completed will conform to the standard if no alterations are made in identified components of the incomplete vehicle ll 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 1 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 IMPORTANT To rely on the compliance representations in this manual the incomplete vehicles must be completed as one of the completed vehicle types designated on the label 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 Ib If the GVWR is modified to less than 3856 kg 8500 Ib additional Federal and or Canadian Motor Vehicle Safety Standards F CMVSS may apply VEHICLE SPECIAL ORDER VSO VEHICLES VSO vehicles can be identified by a number with the letters VSO below the digits in the lower right
75. n this incomplete vehicle accordingly Ford Motor Company makes no representation as to conformity with this Standard STATEMENTS OF CONFORMITY 105 105 105 INFORMATION Incomplete vehicle weight and dimensional information required for center of gravity calculations are available in the Ford Source Book See your local Ford Dealer and refer to appropriate model year and specific vehicle for required information Abbreviation definitions and a vehicle diagram to assist with the equations for the Standard 105 segment are shown on the following page NOTE 105 is an example of a Standard with conformity statements that contain minimum requirements for completed vehicle Unloaded Vehicle Weight UVW see Definitions 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 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
76. ncy or the California Air Resources Board Production fuel systems supplied on incomplete 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 MALFUNCTION INDICATOR LIGHT MIL 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 wo
77. nd unit bodies and their attachments for compatibility with E Series vehicles The statements below are applicable to the following incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less Incomplete E Series Van or Wagon 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 o
78. nt wheel to front TABLE F Vertical distance from ground to chassis CG passenger load Dimensions are inches Model in All E Seriest 48 5 E 150 250 350 SRW Van or Wagon 32 0 Except the E Series Basic Stripped Chassis where the distance E 350 Cutaway 28 0 from the of the front axle to the H point of the driver must be E 450 Cutaway 26 5 measured E 350 450 Basic Stripped Chassis 26 5 TABLE E CG Vertical distance from the ground to the completed vehicle center of gravity Requires Use of Equations A amp B Place the CG of the vehicle from Equation B into the appropriate equations below to determine the allowable range of the CGy If the actual CG from Equation A is within the range calculated the center of gravity location is acceptable Equation for CG Range Model WB in Upper Limit in Lower Limit in E 150 250 138 CGy 1 27 x CGh 59 0 1 27 x CG 77 5 E 350 SRW 138 CGy 1 27 x CGh 60 0 1 27 x CG 80 0 158 CGy 1 27 x CGh 69 5 1 27 x CG 90 7 E SERIES February 2013 13 STATEMENTS OF CONFORMITY 106 108 108 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 br
79. ny School Bus Prep Package regardless of GVWR and to any other incomplete vehicle type if the GVWR Is 4536 kg 10 000 Ib 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 U S Requirements 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 TO OF REAR XK AXLE FOR STRIPPED CHASSIS TO BACK OF ALL WB 601 4 12 7 CUTAWAY CAB 23 7 0 5 bs T hom al 2641 6 104 0 40 00 2 00 138 wb 3149 6 124 0 40 00 2 00 158 wb 3606 8 142 0 40 00 2 00 178 wb gt 7834 N 28 875 gt MAX 4 amp W711103 S900 N SCREW 3 REQ D ES TORQUE TO 0 9 1 3 Nm 8 11 inb G OF FILLER NECK VEHICLE Q CALIFORNIA POINT Z SEE PAGE 47 FUEL TANK FILL PIPE TYPICAL N611131 8439 M4 SELF TAPPING SCREW N611645 S439 M10 SELF TAPPING SCREW ATTACH TO SOUND METAL ON FRAME FUEL TANK TYPICAL OUTBOARD SURFACE OF FRAME RAIL r SECURE WITH TIE STRAPS AS REQUIRED TO VENT HOSE E ROUTE FILL AND VENT _EXISTING 9 7 DIA HOLES USED FOR EXHAUST ON R H
80. o 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 Noequipment 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 ELECTRONIC ACCELERATOR CONTROL Typical The statement below is applicable to the following incomplete vehicle types Incomplete E Series Van or Wagon except Aerial Bucket Prep Package This vehicle when completed will conform to Standard 126 Electronic Stability Control Systems if The vertical center of gravity CGv is less than or equal to 39 2 E 150 250 39 4 E 350 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 E SERIES February 2013 126 131 138 139 If the vertical center of gravity CGv of the vehicle is above 39 2 E 150 250 39 4 E 350 Ford Motor Company makes no representation as to conformity with this Standa
81. of Panel Systems X 2 X 2 X 2 119 8 New Pneumatic Tires for Motor Vehicles X 9 120 Tire Selection and Rims for Motor Vehicles X 9 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 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 X 2 139 New Pneumatic Radial Tires for Light Vehicles X 2 201 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 X 209 Seat Belt Assemblies X 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 X 213 4 Built In Child Restraint System amp 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
82. oint 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 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 Ib 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
83. omplete 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 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 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 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 conclusio
84. only X X 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 Ib or less 3 Applicable to vehicles with a GVWR of 4536 kg 10 000 Ib or less and an unloaded vehicle weight of 2495 kg 5500 Ib or less 4 Injury criteria are applicable to vehicles with a GVWR of 3856 kg 8500 Ib or less and an unloaded vehicle weight UVW of 2495 kg 5500 Ib 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 5 Dynamic Performance Requirements apply to MPVs trucks and buses with a GVWR of 2722 kg 6000 Ib or less 6 Applicable to vehicles with GVWR of 3856 kg 8500 Ib or less and Canada only UVW of 2495 kg 5500 Ib or less and to buses including school bus with a GVWR of 4536 kg 10 000 Ib 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 Ib 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 Ib U S only E SERIES February 2013 U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS INTRODUCTION Informat
85. onvex 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 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 Definitions and the seat back torso angle of the driver seat installed or completed by the subsequent stage manufacture
86. or 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 1 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 t 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 SRW SCHOOL BUS ONLY Z SCHOOL BUS ONLY L minimum frame R required frame length from body holes position from mount hole end of frame 175 25 mm 6 9 1 0 in _ SRW SCHOOL BUS ONLY Four 30 2 mm 1 2 0 1 in holes at frame corners drilled at 45 5 degree angle from horizontal SRW amp DRW SCHOOL BUS ONLY 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 A
87. per 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 2013 TABLE OF CONTENTS U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS Inside Cover INTRODUCTION nee 2 DEFEINITIONS enin pere Saa bei E di Hd 4 5 GENERAL INFORMATION eene 6 Directions u 6 VEHICLE DESCRIPTION a 7 COMPLETED VEHICLE TYPES 8 STATEMENTS OF CONFORMITY 9 38 CANADIAN VEHICLES Vehicle Identification 39 Daytime Running Lamp emm 39 Canadian Radio Frequency Interference 39 EMISSION CERTIFICATION INFORMATION Medium Duty Passenger Vehicles MDPV 40 Frontal Area and Weight Restrictions
88. peration is not restricted by any alteration or added components The SUB horizontal center of gravity must be at or forward of the rear axle centerline for the following vehicles E 350 450 Basic Stripped Chassis E 350 Super Duty Cutaway DRW E 450 Super Duty Cutaway The horizontal center of gravity for the SUB is Atorforward 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 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 w w 25P v gt GVWR CG EQUATION B w We im W x WB GVWR E SERIES PASSENGER LOAD GVWR Ib P Ib 8520 10 000 400 10 001 14 500 500 STATEMENTS OF CONFORMITY FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E SERIES VEHICLES cG
89. ply with Standard 305 Electric Powered Vehicles Electrolyte Spillage and Electrical Shock Protection 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 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 Parts and Accessories Necessary for Safe Operation Liquid Fuel Tanks 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 The statement below is applicable to all incomplete vehicle types except the Basic Stripped Chassis This vehicle when completed will conform to Part 565 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 I
90. pplemental 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 208 Continued Next Page STATEMENTS OF CONFORMITY E SERIES February 2013 208 Continued 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 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 are appropriate compliance representation
91. pplicable 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 Ib 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 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 Ib 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 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 Ca
92. r are located as shown in Figure C 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 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 E SERIES February 2013 15 STATEMENTS OF CONFORMITY 111 111 113 113 114 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 outsid
93. rd The statement below is applicable to the following incomplete vehicle types Incomplete E Series Van Aerial Bucket Prep Package Only This vehicle when completed will conform to Standard 126 Electronic Stability Control Systems if The vertical center of gravity CGv is greater than or equal to 39 4 and less than or equal to 44 25 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 If the vertical center of gravity CGv of the vehicle is below 39 4 or above 44 25 Ford Motor Company makes no representation as to conformity with this Standard 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 determined based upon the components supplied on this incomplete vehicle Accordingly Ford Motor Company makes no representation as to conformity with this Standard The statement below is applicable to all single rear wheel SRW incomplete vehicle types if the GVWR is 4536 kg 10 000 Ib or less if equipped The Tire Pressure Monitoring System TPMS is subject to interference from the addition of metallic structures between the wheel mounted sensor transmitters and the on board receiver Additionally T
94. rd 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 OZONE DEPLETING SUBSTANCE ODS The Clean Air Act of 1990 Section 611 requires any product i e completed vehicle containing or manufactured with any Class Ozone Depleting Substance on or after May 15 1993 must be identified with a clearly and conspicuously attached label Ford Motor Company has eliminated Class ODS from its manufacturing processes All Ford Truck incomplete vehicles will not have Class ODS content Manufacturers including subsequent stage manufacturers are required to label their products if the product including any component whether manufactured by that manufacturer or not contains a Class ODS or if the manufacturer used a Class ODS in the manufacturing of the product In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class 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 VEHICLE EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations the Vehicle Emission Control Information VECI label must be affixed
95. rd 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 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 seatis installed Ford Motor Company makes no representation as to the compliance of the completed vehicle to Standard 201 U S Requirements Section S6 The statements below are applicable to incomplete ve
96. re 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 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 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
97. rformance 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 pro
98. ries 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 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 ad
99. rs If additional tires are installed or the existing tires are replaced by subsequent stage manufacturers they must conform to the requirements of Standard 119 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 STATEMENTS OF CONFORMITY 16 E SERIES February 2013 120 124 126 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 The statements below are applicable t
100. rson who company that CMVSR performs such manufacturing operations on 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 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 complet
101. s 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 Ib GVWR and or over 2495 kg 5500 Ib 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 may affect the deployment of the airbag s and pretensioner s E SERIES February 2013 21 STATEMENTS OF CONFORMITY 715602890 COVER ASSEMBLY 15602B82 ADJUSTER ASSEMBLY UPPER PANEL ASSEMBLY CLOSE D RING COVER AFTER INSTALLATION OF BELT ASSEMBLY TO FRONT W520113 OF VEHICLE TORQUE TO 40 0 6 0 V NOTE 1 2 amp T
102. s 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 2012 REFERENCE INFORMATION FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE ONTARIO L6J 5E4
103. 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 and Figure B After the front seats and B pillar trim are installed the Seat belt system components comply with 208 Adjustment requirements specified by Section 7 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 Section 7 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 Section 7 4 as these requirements apply to comfort and convenience requirements of the seat belt system No actions are taken which would impair the integrity of the seat belt systems and the seat belt warning system The Air Bag Supplemental Restraint System as installed by Ford Motor Company see Figure E 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 affi
104. 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 2013 108 108 108 110 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 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
105. 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 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 advers
106. t 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 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 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
107. tandard 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 The statements below are applicable to all incomplete vehicle types when completed as either a MPV or a Truck with a GVWR of 4536 kg 10 000 Ib 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 gnition key transmission shift interlock locking system gnition 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 115 116 118 118 119 120 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 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 The statement below is a
108. ted 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 E SERIES February 2013 33 301 Thecompleted 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 K1 and K2 The fill hoses hose clamps ground strap and fuel sender unit must be installed to the specification on Figure J No other alteration or modification made to the incomplete vehicle as manufactured by Ford Mot
109. ted as follows The body is mounted securely and is so designed by following structural and package guidelines illustrated in Figure l 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 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
110. this vehicle must comply with the requirements of this Standard 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 The statement below is applicable to buses with a GVWR of 4536 kg 10 000 Ib 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 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 E SERIES February 2013 301 301 301 301 INFORMATION The Un
111. ts The preceding statements for FMVSS 209 are appropriate compliance representations for CMVSS 209 Seat Belt Assemblies if this incomplete vehicle was manufactured for sale or use in Canada In such a case CMVSS 209 paragraphs 2 and 3 4 and 5 14 15 and 7 are substituted for the reference to FMVSS 209 Sections 4 1 b c e g and h respectively 210 210 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 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 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 E Series 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
112. ts 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 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 Canadian Requiremen
113. ump and lines if used with Hydro boost Engine belt drive system Wheelbase NOTE Ford Motor Company provides Type and Type FMVSS CMVSS 105 compliance statements for vehicles built to factory standard or optional specifications Suspension ride height and or spring rate modifications are factors that may affect compliance to this Standard If an alterer or final stage manufacturer modifies the suspension ride height or spring rate of the factory equipped vehicle then they are responsible for engineering analysis or physical testing to ensure compliance and sign off to Standard 105 E SERIES February 2013 11 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 The maximum GAWRs 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 table on this page The service or parking brake pedal assembly o
114. ut 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 cargo carrying 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 V7 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
115. 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 non emergency 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 witho
116. xed 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 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 Ib or the Unloaded Vehicle Weight when completed is over 2495 kg 5500 Ib 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 Ib 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 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 TheAir Bag Su

2014 E-Series Incomplete Vehicle Manual (February

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