Ford Ranger 2020, Mounting Manual

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1 General Information
1.1 About this Publication........................5
1.1.1 New for this BEMM publication
08/2019...........................................................5
1.2 About this Manual...............................6
1.2.1 Introduction....................................................6
1.2.2 Important Safety Instructions.................6
1.2.3 Warnings, Cautions and Notes in This
Manual.............................................................6
1.2.4 How to Use This Manual...........................6
1.3 Commercial and Legal Aspects..........7
1.3.1 Terminology....................................................7
1.3.2 Warranty on Ford Vehicles........................7
1.3.3 Worldwide Harmonized Light-Duty
Vehicle Test Procedures (WLTP)............7
1.3.4 Emissions Performance & In-service
compliance.....................................................7
1.3.5 Whole Vehicle Type Approval
(2007/46/EC) Regulations.......................7
1.3.6 Legal and Vehicle Type Approval...........8
1.3.7 Alternative Type Approval........................8
1.3.8 Legal Obligations and Liabilities............8
1.3.9 General Product Safety
Requirement..................................................8
1.3.10 Product Liability............................................9
1.3.11 Restraints System........................................9
1.3.12 Drilling and Welding....................................9
1.3.13 Minimum Requirements for Brake
system and Load Apportioning Valves
.............................................................................9
1.3.14 Road Safety....................................................9
1.4 Contact Information..........................10
1.5 Conversion Homologation.................12
1.6 Electromagnetic Compatibility
(EMC).................................................13
1.6.1 ...........................................................................1 3
1.7 Vehicle Duty Cycle Guidelines...........14
1.7.1 Vehicle Ride and Handling
Attributes.......................................................14
1.8 Jacking................................................15
1.9 Lifting.................................................16
1.10 Noise, Vibration and Harshness
(NVH).................................................17
1.11 Vehicle Transportation Aids and
Vehicle Storage..................................18
1.12 Package and Ergonomics..................20
1.12.1 General Component Package
Guidelines.....................................................20
1.12.2 Driver Reach Zones...................................20
1.12.3 Driver Field of View...................................20
1.12.4 Conversion Effects on Parking
Aids.................................................................20
1.12.5 Aids for Vehicle Entry and Exit..............20
1.12.6 Worldwide Harmonized Light-Duty
Vehicle Test Procedures (WLTP)
Calculation Inputs.......................................21
1.12.7 Vehicle Dimensions Key...........................22
1.12.8 Recommended Main Load Area
Dimensions...................................................22
1.12.9 WLTP Frontal Area Calculation............22
1.12.10 Registration Plates....................................24
1.13 Package and
Ergonomics—Specifications............25
1.13.1 Recommended Body Dimensions......25
1.13.2 Chassis Cab Body - Basic Dimensions
and Weights.................................................28
1.13.3 Kerb Mass and Payload...........................29
1.13.4 Front, Rear and Side Under-Run
Protection.....................................................29
1.14 Hardware—Specifications................30
1.15 Load
Distribution—Specifications.............31
1.15.1 Load Distribution Calculations - Driver
and Passenger Weight
Distribution....................................................31
1.15.2 Center of Gravity........................................34
1.16 Towing...............................................38
1.16.1 Towing Requirements..............................38
1.16.2 Towing...........................................................38
1.16.3 Towing capacities......................................38
1.16.4 Towbar Types..............................................39
1.16.5 Trailer Nose Weight..................................39
1.16.6 Towing Specifications..............................39
2 Chassis
2.1 Suspension System..........................40
2.2 Brake System.....................................41
2.2.1 General...........................................................41
2.2.2 Brake Hoses..................................................41
2.2.3 Trailer Brake Connection..........................41
3 Powertrain
3.1 Engine................................................42
3.1.1 Engine Selection for Conversions........42
3.1.2 Engine Types ..............................................42
3.2 Fuel System.......................................43
3.2.1 Fuel Filler Pipe Shipping Bracket (if
equipped).....................................................43
3.2.2 Fuel Filler Mounting..................................45
3.2.3 Fuel Filler Vent Hose.................................47
3.2.4 Axle Breather Vent Hose........................48
3.2.5 Selective Catalytic Reduction
System..........................................................48
3.2.6 Filling the Diesel Exhaust Fluid
Tank................................................................49
4 Electrical
4.1 Wiring Installation and Routing
Guides................................................52
4.1.1 Wiring Splicing Procedures....................52
4.2 Battery and Cables............................53
4.2.1 Battery Information...................................53
4.2.2 Generator and Alternator.......................58
4.3 Parking Aid........................................59
4.3.1 Sensor Location.........................................60
4.4 Electronic Engine Controls...............62
4.4.1 Vehicle Speed Output - Tachograph
(if equipped)...............................................62
4.5 Exterior Lighting................................63
4.5.1 Rear Combination lamps.......................64
4.5.2 Rear Fog Lamp...........................................64
4.5.3 ..........................................................................65
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