Ford 2005 E-Series Incomplete Vehicle Manual Download Page 51

E-SERIES 

(May, 2004)

48

E-SERIES 

(May, 2004)

49

EMISSION CERTIFICATION INFORMATION

CAUTION:
U.S.:

2005  MODEL  YEAR  VEHICLES  ARE  EMISSION 

CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS 

OF THE UNITED STATES. FOR EXAMPLE, 

VEHICLES 

CERTIFIED AND LABELED FOR SALE IN CALIFORNIA 

CAN NOT BE SOLD IN THE STATES THAT REQUIRE 

FEDERALLY  CERTIFIED VEHICLES  AND VEHICLES 

CERTIFIED TO  FEDERAL  STANDARDS  CAN  NOT 

BE  SOLD  IN  STATES THAT  REQUIRE  CALIFORNIA 

CERTIFIED VEHICLES.

 IT IS THE SUBSEQUENT  STAGE  

MANUFACTURER’S RESPONSIBILITY  TO  PURCHASE  

A  VEHICLE CERTIFIED FOR THE STATE/AREA IN WHICH 

THE VEHICLE WILL BE SOLD. EPA HAS STATED THAT 

UNDER CERTAIN CIRCUMSTANCES THEY WILL NOT 

ENFORCE THESE  REQUIREMENTS.  FOR  FURTHER 

GUIDANCE  CONSULT  EPA’S  “POLICY  ON  CROSS 

BORDER SALES OF CALIFORNIA VEHICLES.”

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 (MDPV)

EPA  has  adopted  separate  emissions  standards  and 

requirements  for  MDPVs  beginning  in  2005.  A  MDPV  is 

defined as a heavy-duty vehicle with a GVWR under 10,000 

lbs. 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:

All 4.6L and some 5.4L E-Series Vans and Wagons are certified 

to complete light duty <3856 kg [8500 lb] protocol and require 

vehicle weight and frontal area restrictions.

 

Complete 5.4L and 

6.8L Vans and Wagons certified to California >3856 kg [8500 

lb] Medium Duty Vehicle (MDV) protocol also have vehicle 

weight and frontal area restrictions. Modifiers that add weight 

to a vehicle or increase the frontal area of a light-duty/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. Refer 

to guidance under “Emission Control Modifications” in the 

Ford “Body Builders Layout Book”. Starting in 2005, some 

heavy-duty 

incomplete 

vehicles are certified using chassis 

certification  protocol  and  will  require  vehicle  weight  and 

frontal area restrictions (to retain emission certification). If your 

vehicle is affected, the frontal area and unloaded vehicle weight 

information will be found on the VECI label, which is located 

in the engine compartment. Incomplete vehicles with engines 

certified using heavy-duty engine protocol are not limited by 

weight and frontal area restriction for exhaust emissions.
It is important that the final stage manufacturer observe vehicle 

restrictions from vehicle safety requirements, etc., which are 

located  elsewhere  in  this  manual.  Additional  emissions 

certification information is contained in the 

Ford Truck Body 

Builders Layout Book 

for the model year and type of this 

incomplete vehicle.

HIGH ALTITUDE REQUIREMENTS

United States Environmental Protection Agency regulations 

for  the  2005  model  year  do  not  contain  unique  emission 

certification  requirements  for  trucks  that  will  be  sold  or 

delivered  to  customers  for  principal  use  above  1,219  m  

[4,000 ft.].

EMISSION CONTROL HARDWARE

Any body builder, installer, or subsequent stage manufacturer 

must also assure that all emission control hardware furnished 

with incomplete vehicles is on the vehicle and is operational 

and  that  applicable  instructions  for  incorporating  such 

hardware into the completed vehicle’s electrical or mechanical 

systems are strictly followed.
Further,  to  avoid  any  question  of  certification  coverage, 

approval of any modification or use of an engine or vehicle 

which may 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.

IMPORTANT:

For purposes of Government Regulation, a body builder, 

installer, or any subsequent manufacturer may be considered 

a manufacturer.

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 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.

EMISSION CERTIFICATION INFORMATION

Summary of Contents for 2005 E-Series

Page 1: ...KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER 2005 E SERIES INCOMPLETE VEHICLE MANUAL May 2004 5C2S 19A268 AA Incomplete Vehicle Types For This Manual INCOMPLETE E SERIES VANS W...

Page 2: ...X X X X X X 124 Accelerator Control Systems X X X X X 131 School Bus Pedestrian Safety Devices except Multifunction School Activity Bus X 135 Light Vehicle Brake Systems X 10 X 10 X 10 X 10 X 10 201 O...

Page 3: ...of 4536 kg 10 000 lb or less and an unloaded vehicle weight of 2495 kg 5500 lb or less 4 Applicable to vehicles with a GVWR of 2722 kg 6000 lb or less 5 Injury criteria required for vehicles with a G...

Page 4: ...nder the headings Unleaded Gasoline Label page 49 Warranty and Maintenance page 50 and Emission Control Information Label page 50 It is the responsibility of the final stage manufacturer to determine...

Page 5: ...Vehicles MDPV 49 Frontal Area and Weight Restrictions 49 High Altitude Requirements 49 Emission Control Hardware 49 Unleaded Gasoline Label 49 Exterior Noise 50 Tampering with Noise Controls 50 Warra...

Page 6: ...ab 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...

Page 7: ...ada 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 sea...

Page 8: ...l Regulations Vehicles Manufactured in Two or More Stages Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standa...

Page 9: ...requirements The Canadian Motor Vehicle Safety Act and Regulations require installation of an incomplete vehicle certification label with the National Safety mark on it on vehicles manufactured for s...

Page 10: ...5 COMPLETED VEHICLE TYPES COMPLETED VEHICLE TYPES IMPORTANT Ford Motor Company makes no representation that the completed vehicle types listed above are the only vehicle types appropriate for the inc...

Page 11: ...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 alter...

Page 12: ...s added to this vehicle it must conform to the requirements of this Standard 1 Route the cable after the instrument cluster is installed in the vehicle Do not kink the cable Do not bend the cable to a...

Page 13: ...he 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 equat...

Page 14: ...front seats and forward of the centerline of the rear axle Do not restrict the E Series seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 32 The horizontal...

Page 15: ...ound in Table B page 15 The maximum GAWRs and GVWR as identified on the cover of this document are not exceeded with the vehicle weight at Unloaded Vehicle Weight Passenger Load P See E Series Passeng...

Page 16: ...Weight at the rear wheels of the vehicle chassis and cab fuel tanks full pounds Including option weight Wc Weight of the vehicle chassis and cab fuel tanks full pounds Including option weight WB Vehic...

Page 17: ...0 E 350 Basic Stripped Chassis DRW 4013 158 3946 8700 E 350 Basic Stripped Chassis DRW 4470 176 3946 8700 1 2767 kg 6100 lb When completed with 6 or less designated seating positions 2 Maximum unloade...

Page 18: ...e the CGh of the vehicle from Equation B into the appropriate equations below to determine the allowable range of the CGv If the actual CGv from Equation A is within the range calculated the center of...

Page 19: ...es vehicles will meet the FMVSS 108 requirement for DRL s when DRL s are provided Conformity with Standard 108 S 12 Headlamp Concealment Devices are not substantially affected by the design of this in...

Page 20: ...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 Ass...

Page 21: ...of the vehicle If any alteration blocks the rear field of view through the inside mirror Standard 111 may require that the vehicle have a flat glass on the passenger side 111 The statement below is a...

Page 22: ...eplaced conforms to the DOT 3 specifications of the standard and contaminants are not introduced into the hydraulic brake system 118 The statement below is applicable to all incomplete vehicle types n...

Page 23: ...hassis component is accompanied by the addition of equal weight The maximum GAWRs and GVWR as identified on the cover of this document are not exceeded with the vehicle weight at Unloaded Vehicle Weig...

Page 24: ...ment below is applicable to the following incomplete vehicle type if the GVWR is 4536 kg 10 000 lb or less E Series Basic Stripped Chassis Conformity with Standard 201 Occupant Protection in Interior...

Page 25: ...igned by Ford Motor Company to be completed as a walk in van type vehicle Walk in vans are exempt from the impact requirements of Standard 203 Impact Protection for the Driver from the Steering Contro...

Page 26: ...of 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...

Page 27: ...any makes no representation as to conformity with this Standard 207 The statements below are applicable to the following incomplete vehicle types with no front seats Incomplete E Series Van Cutaway E...

Page 28: ...ion 4 5 1 c of Standard 208 No alteration or modifications are made to the body chassis including front bumper drivetrain body mounts or front suspension from the B pillar forward Any front overhead c...

Page 29: ...ted by an occupant Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard 208 Continued 208 The statements below are applicable to the incomplete E...

Page 30: ...to the body chassis including front bumper drivetrain body mounts or front suspension from the B pillar forward Any front overhead console installed on an Incomplete E Series is configured as follows...

Page 31: ...r 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 permanen...

Page 32: ...NEL ASY COVER ALL WAGON VAN MODELS ONLY PASSENGER SEAT RIGHT HAND INSTALLATION ALL CUTAWAY MODELS ONLY 29 5 4 ft lb 35 5 ft lb 40 0 6 0 Nm 29 5 4 ft lb PIA BOLT TORQUE 47 5 7 2 Nm 35 5 ft lb PIA BOLT...

Page 33: ...DR 571479 PASS R H TRACK N011488 S424 STUD 2 REQ D XC25 1560094 A MANUAL SUPPORT ASY COVER FRT ST PVT PIA BOLT TORQUE 40 0 6 0 Nm W705944 S424 SCREW 2 REQ D 55 0 8 3 Nm F7U S14A699DB WIRE ASY 2C24 156...

Page 34: ...POINT A D A F C DIMENSIONS ARE INCHES E E POINT A POINT A DRIVER SEAT PASSENGER SEAT C L VEHICLE B B DRIVER SIDE ONLY TORSO ANGLE 18 DRIVER 21 PASSENGER SEAT BASE SEAT BASE C L OUTSIDE FRONT FASTENER...

Page 35: ...48 S190 SCREW TORQUE 12 0 1 8 Nm 9 1 3 ft lb 14B321 A SNS BRKT ASY A BAG FRT FIGURE E2 E SERIES RESTRAINT CONTROL MODULE FIGURE E3 E SERIES RESTRAINT CONTROL MODULE Sensor system also connected to pyr...

Page 36: ...T OF VEHICLE NOTE SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY THE SPOTWELDS X IN THIS AREA MUST REMAIN INT...

Page 37: ...AXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY DIMENSIONS ARE IN INCHES CUTLINE SECTION EE SECTION FF CUTLINE SECTION GG CUTLINE 533...

Page 38: ...LS DIMENSIONS ARE INCHES C L OUTER EDGE OF TROUGH REGULAR VAN B PILLAR REINFORCEMENT WINDSHIELD HEADER FORWARD CUT LINE 50 8 2 00 SECTION AT C L OF ROOF HEADLINER PLANE FOR VEHICLES NOT EQUIPPED WITH...

Page 39: ...se 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 The statements below are applica...

Page 40: ...9 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 212 INFORM...

Page 41: ...equipped with a driver side door only when completed will conform to Standard 214 Side Impact Protection for that door only if no alterations modifications or replacements are made to the door surroun...

Page 42: ...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 is not substantially a...

Page 43: ...nstrate compliance with FMVSS 301 are loaded pursuant to S7 1 6 of the Standard The test weights of these vehicles comprise the Unloaded Vehicle Weights including the weights of all available regular...

Page 44: ...on Package E Series Cutaway SRW with Gasoline Engine and School Bus Preparation Package This vehicle when completed will conform to Standard 301 Fuel System Integrity if The following fuel system comp...

Page 45: ...licable provisions of Standard 301 301 The statements below are applicable to the following incomplete vehicle type if the GVWR Is 4536 kg 10 000 lb or less E Series Basic Stripped Chassis Conformity...

Page 46: ...ts must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301 The Basic Stripped Chassis is equipped with a Fuel S...

Page 47: ...rers meet the flammability requirements of the Standard 302 The statement below is applicable to the following incomplete vehicle type E Series Basic Stripped Chassis Conformity with Standard 302 Flam...

Page 48: ...mm 0 075 14 GA HRLC STEEL 2 8 GUSSET CROSS SILL TO OUTER SUPPORT L H 1 9mm 0 075 14 GA HRLC STEEL 4 9 GUSSET CROSS SILL TO OUTER SUPPORT R H 1 9mm 0 075 14 GA HRLC STEEL 4 10 SUPPORT CROSS SILL OUTER...

Page 49: ...0 3 86 26 9 1 06 C L 4 C L C L 38 6 1 52 34 9 1 37 110 0 4 33 18 0 0 71 48 0 1 89 122 0 4 80 170 0 6 69 40 3 1 59 172 0 6 77 138 8 5 46 32 6 1 28 71 6 3 13 36 1 1 42 42 7 1 68 425 8 16 76 134 0 5 28 8...

Page 50: ...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 incorporatin...

Page 51: ...partment Incomplete vehicles with engines certified using heavy duty engine protocol are not limited by weight and frontal area restriction for exhaust emissions It is important that the final stage m...

Page 52: ...a Air Resources Board Production fuel systems supplied on incomplete 2005 model year trucks manufactured by Ford Motor Company comply with these requirements If the subsequent stage manufacturer adds...

Page 53: ...ol Label specifications for VIN label is not substantially affected by the design of this incomplete vehicle Accordingly Ford Motor Company makes no representation as to conformity with this requireme...

Page 54: ...E SERIES May 2004 52 SUPPLEMENTS...

Page 55: ...ed to 734 713 2971 Canadian orders should be faxed to 905 670 0844 FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to a specific Model Year and vehicle types The following publication...

Page 56: ...FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE ONTARIO L6J 5E4...

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