Ford 5C2S-19A268-AA manual

DO N OT D ES TR OY : TH IS M AN UA L IS R EQ UI RE D BY LA W. K EE P UN TI L TH E VE HI CL E IS C OM PL ET ED B Y TH E FI NA L ST AG E MA NU FA CT UR ER . Ð 2005 E-SERIES I NC OM P LE T E VE H IC L E MA N UA L Ma y , 2004 5C2S-19A268-AA Incomplete V ehicle T ypes For This Manual INCOMPLETE E-SERIES V ANS & W A GONS E-SERIES CUT A W A Y E-SERIE[...]

Bus (Not T ruc k T ruck Standard School School (Not (W alk-in (1) Number Title of Standard Bus) Bus W alk-In V an) MPV Van) Equip. 101 Control Location, Identication and Illumination X X X X X 102 T ransmission Shift Le ver Sequence, Starter Interlock & T ransmission Braking Eff ect X X X X X 103 Windshield Defrosting & Defogging Systems[...]

E-SERIES (May , 2004) 1 Bus (Not T ruc k T ruck Standard School School (Not (W alk-in (1) Number Title of Standard Bus) Bus W alk-In V an) MPV V an) Equip. 220 School Bus Rollov er Protection X 221 School Bus Body Joint Strength X 222 School Bus P assenger Seating and Crash Protection X 225 Child Restraint Anchorage Systems (U .S. only) X(8) X(8) X[...]

E-SERIES (May , 2004) 2 E-SERIES (May , 2004) 3 Inf or mation in this manual is fur nished pursuant to United States and Canadian saf ety regulations or , in some cases where the information is not required by regulation, is furnished for the con venience of intermediate or nal stage vehicle manuf acturers. Incomplete v ehicles manuf actured for[...]

E-SERIES (May , 2004) 2 E-SERIES (May , 2004) 3 T ABLE OF CONTENTS DEFINITIONS .................................................................................... 4-5 GENERAL INFORMA TION .................................................................... 6 Directions ...............................................................................[...]

E-SERIES (May , 2004) 4 E-SERIES (May , 2004) 5 DEFINITIONS The follo wing denitions are from Title 49, Code of Federal Regulations, P ar ts 567.3, 568.3 and 571.3 where noted. Canadian denitions are from Canada Motor V ehicle Saf ety Regulations, Section 2(1), and are in italics. F ord Motor Company denitions are for the pur pose of this [...]

E-SERIES (May , 2004) 4 E-SERIES (May , 2004) 5 DEFINITIONS Incomplete V ehicle (Canada) – a vehicle (a) other than a vehicle impor ted temporar ily for special pur poses, that is capable of being dr iv en and that consists, at a minimum, of a chassis structure, power train, steering system, suspension system and braking system in the state in wh[...]

E-SERIES (May , 2004) 6 E-SERIES (May , 2004) 7 GENERAL INFORMA TION ST A TEMENTS OF CONFORMITY The Statements of Conf or mity section, which begin on page 9 of this ma nual, lists the F ede ral M otor V eh icle Sa fet y Stan dards in eff ect on the date of manuf acture of this incomplete vehicle that are applicable to the type(s) of completed vehi[...]

E-SERIES (May , 2004) 7 VEHICLE DESCRIPTION VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL CO VER The cover of this manual identifies the three incomplete vehicle con gurations for which compliance representations are contained in this manual. Also , a label is af xed to the cov er which includes the V ehicle Identi cation Number (VIN) f or[...]

E-SERIES (May , 2004) 8 E-SERIES (May , 2004) 9 E-Series E11 Incomplete E-150 W agon X 6 E14 Incomplete E-150 Regular V an X 5 E24 Incomplete E-250 Regular V an X 5 E31 Incomplete E-350 Super Duty W agon X 6 6 E34 Incomplete E-350 Super Duty Regular V an X 5 1 E35 E-350 Super Duty Cutawa y X 3 1 4 2 E39 E-350 Super Duty Basic (Str ipped) Chassis X [...]

E-SERIES (May , 2004) 8 E-SERIES (May , 2004) 9 ST A TEMENTS OF CONFORMITY ST A TEMENTS OF CONFORMITY The following Statements of Conformity apply to vehicles that are produced for sale or impor tation into the United States or Canada. The ter m “Incomplete V ehicle T ypes” in these statements refers to the three types of the vehicles illustrat[...]

E-SERIES (May , 2004) 10 E-SERIES (May , 2004) 11 ST A TEMENTS OF CONFORMITY 10 2 Th e s tat eme nts bel ow ar e a ppl ica ble to al l i nco mpl ete ve hic le type s e xce pt the Bas ic ( Stri ppe d) C has sis: This v ehicle, when completed, will conform to Standard 1 0 2 , T r a n s m i s s i o n S h i f t L e v e r S e q u e n c e , S t a r t e r[...]

E-SERIES (May , 2004) 10 E-SERIES (May , 2004) 11 (1) Measured from top of frame at a point midway between the centerlines of the front and rear axles. (2) Measured rearw ard from the center line of the front axle. ST A TEMENTS OF CONFORMITY 10 3 Th e stat emen t bel ow is app lica ble to all inco mple te ve hic le type s e xce pt the Bas ic ( Stri[...]

E-SERIES (May , 2004) 12 E-SERIES (May , 2004) 13 ST A TEMENTS OF CONFORMITY 10 5 Th e st atem ent s be low are app lic abl e to the fo llo win g incomplete vehicle types if the GVWR is between 35 00 k g [ 7716 lb] an d 36 29 kg [ 800 0 lb ]: • Incomplete E-Series V an or Wa gon This v ehicle, when completed, will conform to Standard 105, Hydraul[...]

E-SERIES (May , 2004) 12 E-SERIES (May , 2004) 13 ST A TEMENTS OF CONFORMITY 10 5 Th e st atem ent s be low are app lic abl e to the fo llo win g in com ple te veh ic le ty pes e xce pt wh en com ple ted as a sc ho ol bu s, and if th e G VWR i s b etw een 36 29 kg [8 000 lb ] an d 6 373 kg [ 14, 050 lb] inc lu sive : • Incomplete E-Series V an or[...]

E-SERIES (May , 2004) 14 E-SERIES (May , 2004) 15 ST A TEMENTS OF CONFORMITY FMVSS 105 & 135 DEFINITIONS AND CALCULA TION ILLUSTRA TION FOR INCOMPLETE E-SERIES VEHICLES L † = Hor izontal distance in inches between the SUB center of gra vity and the of the front axle. P = Passenger load (See E-Series P assenger Load T able page 13). CG v = V e[...]

E-SERIES (May , 2004) 14 E-SERIES (May , 2004) 15 ST A TEMENTS OF CONFORMITY T ABLE A Maximum Unloaded V ehicle Weight (UVW) f or Incomplete V ehic les When Completed (2) (This Information Does Not Appl y T o Vehic les Over 4536 kg [10,000 lb] GVWR) Wheelbase Millimeter Maximum Model [inch] Unloaded V ehicle Weights – Kilogram [pound] E-150 Regul[...]

E-SERIES (May , 2004) 16 E-SERIES (May , 2004) 17 ST A TEMENTS OF CONFORMITY T ABLE C CG hl = Horizontal distance from front axle to cargo CG: Model WB (in) CGhl (in)† Regular V an 138 116 † Extended V an or Extended Wagon 138 126 † Cutaw ay (SRW) 138 121 (DRW) 138 127 † Comm. Cab/Box P artition (DR W) 158 134 † R V (DRW) 158 138 † Comm[...]

E-SERIES (May , 2004) 16 E-SERIES (May , 2004) 17 ST A TEMENTS OF CONFORMITY 10 6 Th e stat emen t bel ow is app lica ble to all inco mple te ve hic le type s: This v ehicle, when completed, will conform to Standard 106, Brak e Hose s, if the br ake hose as sembl ies sup plied by Ford Motor Company are not remov ed, relocated, altered, or modied[...]

E-SERIES (May , 2004) 18 E-SERIES (May , 2004) 19 ST A TEMENTS OF CONFORMITY 10 8 Th e st atem ent s be low are app lic abl e to the fo llo win g in comp let e ve hic le typ e: • Cutaway This v ehicle, when completed, will conform to Standard 108, Lamps, Reflectiv e Devices , and Associated Equipment, if all the required lighting equipment as ind[...]

E-SERIES (May , 2004) 18 E-SERIES (May , 2004) 19 ST A TEMENTS OF CONFORMITY 10 8 Th e st atem ent s be low are app lic abl e to the fo llo win g in comp let e ve hic le typ e: • E-Series Basic (Stripped) Chassis: Conf or mity with Standard 108, Lamps, Reflective De vices, and Associated Equipment, is not substantially aff ected by the design of [...]

E-SERIES (May , 2004) 20 E-SERIES (May , 2004) 21 ST A TEMENTS OF CONFORMITY 11 1 Th e st atem ent s be low are app lic abl e to the fo llo win g incomplete vehic le type when equipped with a at gl ass mir ror on the pa ssen ger -si de: • Incomplete E-Series V an This v ehicle, when completed, will conform to Standard 111, Rear view Mirrors , [...]

E-SERIES (May , 2004) 20 E-SERIES (May , 2004) 21 ST A TEMENTS OF CONFORMITY 12 4 Th e s tat eme nts bel ow ar e a ppl ica ble to al l i nco mpl ete ve hic le type s: This v ehicle, when completed, will conform to Standard 124, Accelerator Control Systems, if: • No alterations are made to the accelerator pedal, mounting hardware, adjustable pedal[...]

E-SERIES (May , 2004) 22 E-SERIES (May , 2004) 23 • The horizontal center of gr avity f or the SUB is: – At or forw ard of the rear axle centerline. The vertical center of gravity for the completed vehicle at Unloade d V ehicle We ight + 397 l b passe nger l oad CGv (Equation A) must not exceed 36.0 inches, when measured from the ground. – Be[...]

E-SERIES (May , 2004) 22 E-SERIES (May , 2004) 23 ST A TEMENTS OF CONFORMITY 20 2 Th e st atem ent s be low are app lic abl e to the fo llo win g incomplete vehicle types if the GVWR is 4536 kg [1 0,00 0 l b] o r le ss: • Incomplete E-Series V an or Wagon when equipped with front seats • Cuta way when equipped with front seats This vehicle when[...]

E-SERIES (May , 2004) 24 E-SERIES (May , 2004) 25 20 5 Th e stat emen t bel ow is app lica ble to all inco mple te ve hic le type s, e xce pt the Bas ic ( Str ippe d) C has sis: This vehicle , when completed, will conform to St an da rd 2 05 , G l az in g M a te r ia ls, i f n o alte ra ti on s to or replacements of the installed glazing materials [...]

E-SERIES (May , 2004) 24 E-SERIES (May , 2004) 25 ST A TEMENTS OF CONFORMITY 20 7 Th e st atem ent s be low are app lic abl e to the fo llo win g incomplete vehicle types when equipped with un trim med fr ont sea ts: • Incomplete E-Series V an • Cuta way This vehicle when completed, will conform to Standard 207, Seating Systems, if: • No chan[...]

E-SERIES (May , 2004) 26 E-SERIES (May , 2004) 27 ST A TEMENTS OF CONFORMITY 20 8 NO T E An RCM (crash sensor and restraints control module) is located under the dr iver's seat. Care must be used to av oid damage to the RCM and sensor wir ing dur ing remov al or reinstallation of the dr iver's seat. Refer to Figure E on page 33. 20 8 Th e[...]

E-SERIES (May , 2004) 26 E-SERIES (May , 2004) 27 ST A TEMENTS OF CONFORMITY • The Air Bag Supplemental Restraint System as originally installed (see Figure E on page 33), is not remov ed, relocated, altered, or modied in any wa y . • The Air Bag Supplemental Restraint System Inf or mation Labels that are afxed to the front sun visors are[...]

E-SERIES (May , 2004) 28 E-SERIES (May , 2004) 29 ST A TEMENTS OF CONFORMITY • No compressible material is installed between front seat assembly and the oor pan. • No additional components or modications are made to the areas dened as the Occupant Protection Zone shown in Figure D on page 32. • The Air Bag Supplemental Restraint Syst[...]

E-SERIES (May , 2004) 28 E-SERIES (May , 2004) 29 ST A TEMENTS OF CONFORMITY • The Air Bag Supplemental Restraint System as installed by Ford Motor Company (see Figure E on pag e 33) is n ot re mov ed, reloc ated, modi ed o r alt ered in an y way . Fo r d t ec h n ic a l bu l l et i n p r oc e d ur e s fo r relocating the oor-mounted restra[...]

E-SERIES (May , 2004) 30 E-SERIES (May , 2004) 31 ST A TEMENTS OF CONFORMITY CRITICAL CONTROL ITEM VIEW A A VIEW B B A VIEW A CRITICAL CONTROL ITEM FRONT OF VEHICLE FRONT OF VEHICLE 3C24-15602B82 ADJ. ASY. PANEL ASY. UPPE R F65B-15602B90 COVER ASY. 3C24-1560262 COVER ASY. 1 REQ’D. EA. SIDE N806773-S190 NUT TORQU E 40.0 ± 6.0 Nm 15611B0 9 BELT AN[...]

E-SERIES (May , 2004) 30 E-SERIES (May , 2004) 31 ST A TEMENTS OF CONFORMITY FIGURE B – E-SERIES FRONT SEA T INST ALLA TION POWER L.H. SHOWN SEA T ASY . N802351-S424 STUD 2 REQ’D. 2C24-1561701-A POWER TRACK A FRT . ST . 56912-S58 SCREW 4.2 x 19 T A PPING N800937-S424 NUT & W ASHER ASY . 2 REQ’D. TO RQUE 55.0 8.3 Nm N620481-S58 NUT M8 x 1.[...]

E-SERIES (May , 2004) 32 E-SERIES (May , 2004) 33 ST A TEMENTS OF CONFORMITY FIGURE D – E-SERIES OCCUP ANT PRO TECTION ZONE SRP INFORMA TION POINT A (SEA T POSITION IS 10.0mm [0.39 IN] FOR WARD (SEA T POSITION IS A T THE MIDPOINT OF REARMOST POSITION) OF A V AILABLE TRA VEL) A B C D E F MIN. MAX. DRIVER – SEA T (V AN AND CUT A W A Y) 217.8 105.[...]

E-SERIES (May , 2004) 32 E-SERIES (May , 2004) 33 FIGURE E1 – E-SERIES SUPPLEMENT AL RESTRAINT SYSTEM (Air Bags, Sensors, and Wiring) ST A TEMENTS OF CONFORMITY  [...]

E-SERIES (May , 2004) 34 E-SERIES (May , 2004) 35 ST A TEMENTS OF CONFORMITY CUT LINE SECTION BB CUT LINE CUT LINE SECTION CC SECTION DD CUT LINE CUT LINE SECTION AA B A FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANEL S. THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY . THE SPOTWELDS ([...]

E-SERIES (May , 2004) 34 E-SERIES (May , 2004) 35 ST A TEMENTS OF CONFORMITY E F FRONT OF VEHICLE THE SPOTWELDS ( X ) IN THIS AREA MUST REMAIN INTACT. G NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIE W FOR THE PURPOSE OF CLARITY. [ ] DIMENSIONS ARE IN INCHES CUTLIN E SECTION EE SE[...]

E-SERIES (May , 2004) 36 E-SERIES (May , 2004) 37 ST A TEMENTS OF CONFORMITY FIGURE G3 – ROOF P ANEL REMOV AL AREA – E-SERIES END OF ROOF EXTENDED V A N END OF ROOF EXTENDED V A N OR WAG ON REGULAR V A N NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANEL S. [ ] DIMENSIONS ARE INCHES C L OUTER EDGE OF TROUGH REGULAR V AN "B" PI[...]

E-SERIES (May , 2004) 36 E-SERIES (May , 2004) 37 ST A TEMENTS OF CONFORMITY 20 9 Th e st atem ent s be low are app lic abl e to the fo llo win g in comp let e ve hic le typ es w ith fr ont sea t(s ): • Incomplete E-Series V an or Wagon • Cuta way This v ehicle, when completed, will conform to Standard 209, Seat Belt Assemblies , if: • No alt[...]

E-SERIES (May , 2004) 38 E-SERIES (May , 2004) 39 ST A TEMENTS OF CONFORMITY 21 0.1 (Co ntin ued ) This v ehicle, when completed, will conform to Standard 210.1, User-Ready T ether Anchorages for Restraint Systems, if: • No alter nations are made to the front passenger seat tet her anch orag es a nd ac cess to the ancho rage s is not restricted; [...]

E-SERIES (May , 2004) 38 E-SERIES (May , 2004) 39 ST A TEMENTS OF CONFORMITY 21 2/ Th e st ate ment bel ow is app lica ble to the f ollo wi ng 21 9 in co mp le te ve hi c le ty pe i f th e GV WR is 4 53 6 kg [ 10, 00 0 lb ] or le ss: • E-Series Basic (Stripped) Chassis T h e B a s i c ( S t r i p p e d ) C h a s s i s i s d e s i g n e d by F o r[...]

E-SERIES (May , 2004) 40 E-SERIES (May , 2004) 41 ST A TEMENTS OF CONFORMITY 2 19 See combined statements under “212/219” for all ve hic le type s. 22 0 Th e st atem ents bel ow are app lica ble to the Cut aw ay equip ped with the School Bus Prep P acka ge when co mple ted as a sc ho ol b us : The Cutaw ay body str ucture as manuf actured by Fo[...]

E-SERIES (May , 2004) 40 E-SERIES (May , 2004) 41 30 1 Th e st atem ent s be low are app lic abl e to the fo llo win g in comp let e v ehic le ty pes if th e v ehi cl e G VWR is 45 36 kg [10 ,00 0 lb ] or le ss: • Incomplete E-Series V an or Wagon This v ehicle, when completed, will conform to Standard 301, Fuel System Integrity , if: • The fol[...]

E-SERIES (May , 2004) 42 E-SERIES (May , 2004) 43 ST A TEMENTS OF CONFORMITY 30 1 (C onti nue d) 30 1 (C onti nue d N ex t P a ge) † T emporary remov al of the front bumper and front b umper mounting system during manuf acture and reinstallation in accordance with the instr uctions pro vided in the F ord T r uck Shop Man ual should not adversely [...]

E-SERIES (May , 2004) 42 E-SERIES (May , 2004) 43 ST A TEMENTS OF CONFORMITY † T emporary remov al of the front bumper and front b umper mounting system during manuf acture, and reinstallation in accordance with the instructions provided in the F ord T r uck Shop Manual , sho uld not adversely affect compliance of the completed v ehicle to Standa[...]

E-SERIES (May , 2004) 44 E-SERIES (May , 2004) 45 ST A TEMENTS OF CONFORMITY • T he bod y ins tall ed b y a subs equ ent st age manu f actu rer and the Ford inst alled f uel syst em compo nents ar e located and mounted as f ollows: – The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specifie[...]

E-SERIES (May , 2004) 44 E-SERIES (May , 2004) 45 ST A TEMENTS OF CONFORMITY 30 1 Th e stat eme nts be lo w are ap pli cab le to t he ov er 45 36 kg [10 ,000 lb] GVW R E-35 0 DR W and E- 450 Cu taw ay wh en equ ipp ed wit h Die sel Engi ne an d Sc hoo l Bus Pr ep P a cka ge and com plet ed as a sc hoo l b us: This v ehicle when completed will confo[...]

E-SERIES (May , 2004) 46 E-SERIES (May , 2004) 47 ST A TEMENTS OF CONFORMITY FIGURE J1 – E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STR UCTURE 8 3 9 11 12 8 1 9 2 7 9 4 16 FORD PROVIDED ISOLATORS (6 ) 14 13 10 778.8 [ 30.66] 12.8 [.50] 16 1. 4 [6.35] 5 9 6 8 7 25.4 [1.00] TYPICAL 268. 0 [ 10.55] 164.3 [6.47] 147.8 [5.82] 163. 8 [6.45] 23 75 . 0 [ [...]

E-SERIES (May , 2004) 46 E-SERIES (May , 2004) 47 ST A TEMENTS OF CONFORMITY FIGURE J2 – E-SERIES DIESEL SCHOOL BUS FUEL SYSTEM AND FLOOR STR UCTURE 9 10 3 5 6 7 WELD SHEET METAL RELIEF AFTER FORMING GUSSET CROSS SILL TO OUTER SUPPORT R.H. SHOW N L.H. SYMETRICALLY OPPOSITE. SUPPORT CROSS SILL OUTER L.H. SHOWN. R.H. SYMETRICALLY OPPOSITE. C VIEW C[...]

E-SERIES (May , 2004) 48 E-SERIES (May , 2004) 49 ST A TEMENTS OF CONFORMITY CANADIAN VEHICLES (V ehicles to be completed for sale or use in Canada) VEHICLE IDENTIFICA TION Ref er to the V ehicle Description section of this manual on page 7, f or additional information. Incomplete vehicles produced by F ord Motor Company require, f or cer tain appl[...]

E-SERIES (May , 2004) 48 E-SERIES (May , 2004) 49 EMISSION CER TIFICA TION INFORMA TION CA UTION: U .S.: 2005 MODEL YEAR VEHICLES ARE EMISSION CER TIFIED FOR REGISTRA TION IN SPECIFIC AREAS OF THE UNITED ST A TES. FOR EXAMPLE, VEHICLES CERTIFIED AND LABELED FOR SALE IN CALIFORNIA CA N N OT B E SO L D I N TH E S T A T E S TH A T R E QU IR E FEDERALL[...]

E-SERIES (May , 2004) 50 E-SERIES (May , 2004) 51 EMISSION CERTIFICA TION INFORMA TION EXTERIOR NOISE Ne w v eh icle s w hich ha ve a gros s v eh icle we ight ra ting in e xces s of 4536 kg [10,000 lb], include a par tially or wholly enclosed operator’ s compar tment, and are manuf actured f or use in the Unit ed State s, m ust com ply with U .S.[...]

E-SERIES (May , 2004) 50 E-SERIES (May , 2004) 51 CALIFORNIA FUEL V APOR RECO VER Y Calif or nia regulations require that the v ehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstr ucted access to the fill pipe. Fuel filler pipes installed per Figure I on page 44 will comply with the “Specications Fo[...]

E-SERIES (May , 2004) 52 SUPPLEMENTS[...]

REFERENCE INFORMA TION FORD TR UCK BOD Y BUILDERS LA Y OUT BOOK Throughout this manual y ou will nd references to inf or mation f ound in the Ford T ruck Body Builders La yout Book . Additional Design Recommendations and specications are also provided to assist subsequent stage man ufacturers in completing chassis cab and incomplete vehicles [...]

FORD MO TOR COMP ANY THE AMERICAN RO AD DEARBORN, MI 48121 FORD MO TOR COMP ANY OF CANAD A LIMITED THE CANADIAN RO AD OAKVILLE, ONT ARIO L6J 5E4[...]