DO NOT DESTROY: THIS MANUAL IS REQUIRED BY

LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY

THE FINAL STAGE MANUFACTURER.

2004
E-SERIES
INCOMPLETE VEHICLE MANUAL

Incomplete Vehicle Types

For This Manual

INCOMPLETE
E-SERIES
VANS &
WAGONS

E-SERIES
CUTAWAY
& CHASSIS
CAB

E-SERIES
BASIC
CHASSIS

May, 2003
4C2S-19A268-AA
 U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS
(APPLICATION BY VEHICLE TYPE)
Bus (Not Truck Truck
Standard School School (Not (Walk-in (1)
Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.
101 Control Location, Identification and Illumination X X X X X
102 Transmission Shift Lever Sequence, Starter
Interlock & Transmission Braking Effect X X X X X
103 Windshield Defrosting & Defogging Systems X X X X X
104 Windshield Wiping and Washing Systems X X X X X
105 Hydraulic and Electric Brake Systems X X X X X
106 Brake Hoses X X X X X X
108 Lamps, Reflective Devices & Associated Equipment X X X X X X
108.1 Headlamps (Canada only) X X X X X
110 Tire Selection and Rims (U.S. only) X X X X X X
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 Hydraulic Brake Fluids X X X X X X
118 Power Operated Window, Partition, and Roof
Panel Systems X(2) X(2) X(2)
119 New Pneumatic Tires for Vehicles Other
Than Passenger Cars X
120 Tire Selection and Rims for Motor Vehicles
Other Than Passenger Cars X X X X X X
124 Accelerator Control Systems X X X X X
131 School Bus Pedestrian Safety Devices X
135 Light Vehicle Brake Systems X(10) X(10) X(10) X(10) X(10)
201 Occupant Protection in Interior Impact X(2)(9) X(2)(9) X(2) X(2) X(2)(9)
202 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 X
206 Door Locks and Door Retention Components X X X
207 Seating System X X X X X
208 Occupant Crash Protection X(6)(5) X(6)(5) X(6)(5) X(6)(5) X(6)(5) X
209 Seat Belt Assemblies X X X X
210 Seat Belt Assembly Anchorages X X X X X
210.1 User-Ready Tether Anchorages for Restraint
Systems (Canada only) X(8) X(8) X(8) X(8)
210.2 Lower Universal Anchorage Systems for Restraint
Systems and Booster Cushions (Canada only) X(8) X(8) X(8) X(8)
212 Windshield Mounting X(2) X(2) X(2) X(2)
213 Child Restraint Systems X X X X X X
214 Side Impact Protection X(2)(7) X(2) X(2)(7) X(2)(7)
217 Bus Window Retention and Release X X
219 Windshield Zone Intrusion X(2) X(2) X(2) X(2)

(Continued on Page 1)

E-SERIES (May, 2003)

 U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS
(APPLICATION BY VEHICLE TYPE)
(Continued from Inside Front Cover)

Bus (Not Truck Truck

Standard School School (Not (Walk-in (1)
Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.
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 X(8) X(8) X(8) X(8) X(8)
301 Fuel System Integrity X(2) X X(2) X(2) X(2)
301.1 LPG Fuel Systems (Canada only) X X X X X
301.2 CNG Fuel Systems (Canada only) X X X X X
302 Flammability of Interior Materials X X X X X
303 Fuel System Integrity of CNG Vehicles (U.S. only) X(2) X X(2) X(2) X(2)
304 CNG Fuel Container (U.S. only) X
PART Vehicle Identification Number (U.S. only) X X X X X
565.4
1106 Noise Emissions (Canada only) X X X X X

(1) Applicable to Equipment for use on applicable vehicle types. (6) Injury criteria is optional for some vehicles where they are
(2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] not required.
or less. (7) Dynamic Performance Requirements apply to MPV, truck or a
(3) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or bus with a GVWR of 2722 kg [6000 lb] or less.
less and an unloaded vehicle weight of 2495 kg [5500 (8) Tether anchors and latch/ISO Fix lower anchors that are installed
lb] or less. voluntarily or by regulation must comply with this Standard.
(4) Applicable to vehicles with a GVWR of 2722 kg [6000 lb] or (9) The requirements of section S6 of Standard Number 201 (United
less. States) do not apply to buses with a GVWR more than 3860 kg
(5) Injury criteria required for vehicles with a GVWR of 3856 kg [8510 lb] and walk-in van type trucks.
[8500 lb] or less and an unloaded vehicle weight of 2495 kg (10) Applicable to vehicles with a GVWR of 3500 kg [7716 lb] or
[5500 lb] or less except, in U.S., walk-in van-type trucks and less.
vehicles designed to be sold exclusively to the U.S. Postal
Service and, in Canada, vehicles manufactured for operation
by persons with disabilities.

E-SERIES (May, 2003) 1

 INTRODUCTION

Information in this manual is furnished pursuant to United States and Canadian

safety regulations or, in some cases where the information is not required by
regulation, is furnished for the convenience of intermediate or final stage vehicle
manufacturers. Incomplete vehicles manufactured for sale or importation into
the U.S., are specially equipped for the United States. The descriptions and
statements contained in the manual relate only to motor vehicle safety standards
issued under the National Traffic and Motor Vehicle Safety Act of 1966 as
amended.
An incomplete vehicle manufactured for sale or importation into Canada is
specially equipped for Canada. This vehicle conforms to the applicable Canadian
Motor Vehicle Safety Standards (CMVSS) on the date of manufacture printed on
the cover of this manual. Requirements unique to vehicles for use in Canada are
identified in the Statements of Conformity and the “Canadian Vehicles”, page 55.
The Emission Certification Information section of this manual contains information
regarding conformity to exhaust emission regulations of the United States,
Canada, and the State of California and fuel economy regulations of the United
States.
This manual should not be relied upon with respect to compliance with any
regulation of the Federal Highway Administration or regulations issued pursuant
to the Occupational Safety and Health Act (OSHA) or any other federal,
state, or local regulations governing the performance or construction of motor
vehicles (except for those requirements shown under the heading “Warranty
and Maintenance,” page 57, “Emission Control Information Label,” page 58 and
“Unleaded Gasoline Label,” page 57). 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 Section
567.5 of Title 49, Code of Federal Regulations, that the completed vehicle conforms to
all applicable Federal Motor Vehicle Safety Standards and that all applicable federal,
state and California emission/noise standards are conformed with.
Ford Motor Company does not make any representation as to the appropriateness
of modifications for any particular application other than expressly stated herein.
Intermediate and final stage manufacturers must exercise proper engineering judgment
to determine if a modification is appropriate for their specific application.

IMPORTANT:
UNITED STATES AND CANADIAN VEHICLES
Alterations to a chassis cab or 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 chassis cab vehicle.

INTRODUCTION 2 E-SERIES (May, 2003)

 TABLE OF CONTENTS

GENERAL INFORMATION.................................................................... 4
Directions........................................................................................... 4

VEHICLE DESCRIPTION ..................................................................... 5

COMPLETED VEHICLE TYPES .............................................................6

DEFINITIONS .................................................................................... 7-8

STATEMENTS OF CONFORMITY................................................... 9-54

CANADIAN VEHICLES
Vehicle Identification ........................................................................ 55
Daytime Running Lamp (DRL)......................................................... 55
Canadian Radio Frequency Interference (RFI)................................ 55

EMISSION CERTIFICATION INFORMATION

Exhaust Emission and Fuel Economy ............................................. 56
Medium Duty Passenger Vehicles (MDPV).......................................56
Frontal Area and Weight Restrictions ...............................................56
High Altitude Requirements ..............................................................56
Emission Control Hardware ..............................................................56
Unleaded Gasoline/Fuel Label ........................................................ 57
Exterior Noise .................................................................................. 57
Tampering with Noise Controls .........................................................57
Warranty and Maintenance.............................................................. 57
Evaporative Emissions..................................................................... 57
Malfunction Indicator Light (MIL) ..................................................... 57
Ozone Depleting Substance (ODS)..................................................58
Emission Control Information Label................................................. 58
California Fuel Vapor Recovery ....................................................... 58
California Emission Control Label.................................................... 58
Radio Frequency Interference (RFI) ................................................ 59

REFERENCE INFORMATION ............................................. Back Cover

E-SERIES (May, 2003) 3 TABLE OF CONTENTS

 GENERAL INFORMATION

Information in this section is provided pursuant to Part 568 of Each Chassis Cab (see definition on page 7) manufactured
Title 49, Code of Federal Regulations. “Vehicles Manufactured by Ford has a label affixed to the driver-door lock pillar that
in Two or More Stages.” Part 568 specifies that final stage identifies the following:
manufacturers must complete vehicles in compliance with • The specific Federal Motor Vehicle Safety Standards
all applicable Federal Motor Vehicle Safety Standards, and to which the Chassis Cab conforms, as of the date of
Section 6 of the Canadian Motor Vehicle Safety Regulations manufacture.
(CMVSR), Vehicles Manufactured in Stages. Section 6.6 of
the CMVSR provides labeling requirements for vehicles that • The specific Federal Motor Vehicle Safety Standards to
are to be sold in Canada. which the Chassis Cab will conform when completed as
specified in this manual.
• The date of manufacture (month/year) of the Chassis Cab
by Ford Motor Company

DIRECTIONS
STATEMENTS OF CONFORMITY
The Statements of Conformity section, which begin on page 9
of this manual, lists the Federal Motor Vehicle Safety Standards IMPORTANT:
in effect on the date of manufacture of this incomplete vehicle
that are applicable to the type(s) of completed vehicles into To rely on the compliance representations in this manual,
which this incomplete vehicle may be manufactured. This the incomplete vehicles must be completed as one of
date is shown on the label affixed to the cover of this manual. the completed vehicle types designated on the label
These statements, in most cases, apply to specific types of affixed to the cover of this manual, and must not exceed
incomplete or completed vehicles and identify GVWR and the specified GVWR, GAWRs, or the Unloaded Vehicle
UVW weight ranges. Weight limits when specified in this manual.

The incomplete vehicle type is identified by the 5th, 6th, and

7th digits of the Vehicle Identification Number (VIN); see VEHICLE SPECIAL ORDER (VSO) VEHICLES
page 5. The completed vehicle types to which this incomplete VSO vehicles can be identified by a six digit number with the
vehicle may appropriately be completed is printed on the letters VSO below the digits in the lower right corner of the
label, under the heading “May Be Completed As,” that is Incomplete Vehicle Label which is affixed to the driver-door
affixed to the cover of this document. The Completed Vehicle lock pillar. See the sample label on page 5.
Types charts on page 6 identifies how various incomplete
vehicles with an Optional Prep Packages or a Trim Code, The Statements of Conformity section of this manual includes
may be completed. compliance representations for certain VSO vehicles. These
vehicles are identified in the charts on page 6. Other VSO
Each statement of conformity is identified by a safety standard vehicles may require additional Statements of Conformity
number located at the left margin. Because there may be which will be in the Supplement Section of this manual.
multiple statements of conformity for each safety standard,
use care to select the appropriate statement. Unique CMVSS FORD TRUCK ASSISTANCE
requirements will be identified at the conclusion of the
representations for a particular safety standard. Throughout this manual you will find references to information
found in the Ford Truck Body Builders’ Layout Book. Additional
Compliance statements provided in this manual are of Design Recommendations and specifications are also provided
the three following types: to assist subsequent stage manufacturers in completing
Type I • A statement that the vehicle, when completed, chassis cab and incomplete vehicles. To obtain a free copy
will conform to the standard if no alterations are of this publication on CD-ROM or to receive an order form
made in identified components of the incomplete for additional CD-ROM’s or books please visit our website at
vehicle. www.fleet.ford.com/truckbbas/. Under Publications select Body
Type II • A statement of specific conditions of final Builders Order Forms. All dealer requests can be handled
manufacture under which the incomplete vehicle online. All other U.S. orders should be faxed to (734) 713-2971.
manufacturer specifies that the completed vehicle Canadian orders should be faxed to (905) 670-0844.
will conform to the standard. The Ford Truck Body Builder Advisory Service may be
Type III • A statement of conformity with the standard is consulted regarding information contained in this manual.
not substantially affected by the design of the • Call (877) 840-4338
incomplete vehicle, and that the incomplete vehicle • Fax (313) 594-2633
manufacturer makes no representation as to
conformity with the standard. • E-Mail [email protected] or at the BBAS website –
www.fleet.ford.com/truckbbas/
Include your name, company and telephone number with
all inquiries. If requesting written materials, include your
mailing address.

GENERAL INFORMATION 4 E-SERIES (May, 2003)

 VEHICLE DESCRIPTION

INCOMPLETE VEHICLE MANUAL COVER California Air Resources Board (CARB), requires a Vehicle
The cover of this manual identifies the three incomplete Identification Number (VIN) Label having a non-contact, bar-
vehicle configurations for which compliance representations code, reading wand capability. The bar-code directly below
are contained in this manual. Also, a label is affixed to the the VIN on the incomplete vehicle label, when provided, will
cover which includes the Vehicle Identification Number (VIN) comply with this regulation. See page 58 for location and
for the specific vehicle to which this manual belongs. The label other requirements.
identifies the following information which pertains only to the The Canadian Motor Vehicle Safety Act and Regulations
vehicle with the corresponding VIN. require installation of an incomplete vehicle certification label
• The GVWR. with the National Safety mark on it on vehicles manufactured
for sale in Canada. A label representative of those installed
• The front and rear GAWRs. by Ford assembly plants is shown below.
• Tire and wheel size.
OPTIONAL PREP PACKAGES
• Cold tire inflation pressure (kPa/PSI).
Incomplete vehicles produced by Ford Motor Company, in
• Completed vehicle type(s) into which the incomplete some instances, are equipped with Optional Prep Packages.
vehicle may be manufactured. These include the Ambulance Prep, School Bus Prep,
• Optional prep package when the vehicle is so Motorhome Prep, and Shuttle Bus Prep. The completed
equipped. vehicle type charts on page 6 will identify incomplete vehicles
and the optional prep packages or trim codes that may be
INCOMPLETE VEHICLE LABEL required by Ford if final stage manufacturers wish to rely on
All E-Series incomplete vehicles manufactured by Ford Motor the Statements of Conformity or, in some cases, preserve the
Company will have an incomplete vehicle label affixed to the Ford new vehicle warranty.
driver-door lock pillar, except Basic (Stripped) Chassis. The If an incomplete vehicle is equipped with an optional prep
incomplete vehicle label for the Basic (Stripped) Chassis is package, both the incomplete vehicle label affixed to the
affixed to the front structure. The sample labels, shown below, vehicle and the label on the front of this manual will identify
are typical of that provided. the Prep Package.
The 5th, 6th, and 7th digits of the Vehicle Identification
Number (VIN) will identify the incomplete vehicle type. These
three digits are used in the Completed Vehicle Types charts
on page 6.

DATE OF
INCOMPLETE VEHICLE MANUFACTURED BY
MANUFACTURE FORD MOTOR COMPANY
MADE IN U.S.A.
DATE : 01/04 GVWR: 11000LB/4989KG
FRONT GAWR: 4200LB REAR GAWR: 8250LB
1905KG WITH 3742KG WITH
VEHICLE TYPE
(SEE CHART LT215/85R16D TIRES LT215/85R16D TIRES
ON PAGE 6) 16X6K RIMS 16X6K RIMS
AT 58 PSI COLD AT 65 PSI COLD DUAL BAR CODE V.I.N.
(CALIFORNIA)
VIN: 1FDKE37HZ4HA24638

EQUIPPED WITH THE FORD

AMBULANCE PREP PKG. VSO
OPTIONAL 410047 VEHICLE
PREP PACKAGE
EXTERIOR PAINT COLORS VSO
WB TYPEGVW BODY TRANS AXLE TAPE SPRINGS
161 F379 AJ8 E 65 NY
F85B1520472AB

TYPICAL E-SERIES - U.S.

DATE OF
MANUFACTURE

DATE 01/04

VEHICLE TYPE
(SEE CHART
ON PAGE 6) VIN: 1FDKE37HZ4HA24639

1FDKE37HZ4HA24639

VSO
VEHICLE
1019
VSO

TYPICAL E-SERIES - CANADA

INCOMPLETE VEHICLE LABELS

E-SERIES (May, 2003) 5 VEHICLE DESCRIPTION

 COMPLETED VEHICLE TYPES

INCOMPLETE VEHICLES COMPLETE VEHICLES

(WALK-IN VAN)

(AMBULANCE)

SCHOOL BUS)
5TH, 6TH, 7TH

SCHOOL BUS
VIN DIGIT

BUS (NOT
TRUCK

TRUCK

MPV

MPV
E-Series
C35 E-350 Chassis Cab X
C45 E-450 Chassis Cab X
E11 Incomplete E-150 Wagon X 6
E14 Incomplete E-150 Regular Van X 5
E24 Incomplete E-250 Regular Van X 5
E31 Incomplete E-350 Super Duty Wagon X 6 6
E34 Incomplete E-350 Super Duty Regular Van X 5 1
E35 E-350 Super Duty Cutaway X 3 1 4 2
E39 E-350 Super Duty Basic (Stripped) Chassis X
E45 E-450 Super Duty Cutaway X 3 1 4 2
E49 E-450 Super Duty Basic (Stripped) Chassis X
S24 Incomplete E-250 Extended Van X 5
S31 Incomplete E-350 Super Duty Extended Wagon X 6 6
S34 Incomplete E-350 Super Duty Extended Van X 5 1 5

(1) Ambulance Prep Package.

IMPORTANT: (2) School Bus Prep Package.
Ford Motor Company makes no representation that the (E-350 available on 9600 lb GVWR SRW, and 11,500 lb GVWR
completed vehicle types listed above are the only vehicle DRW only).
types appropriate for the incomplete vehicles listed. (3) Motorhome Prep Package.
However, if a unit is completed as a vehicle type other
than as listed above, the Statements of Conformity may (4) Shuttle Bus Prep Package.
not be applicable. (5) Recreational Van.
(6) Center Aisle Seat Prep Package

COMPLETED VEHICLE TYPES 6 E-SERIES (May, 2003)

 DEFINITIONS

The following definitions are from Title 49, Code of Federal Regulations, Part 571.3 except where noted.
Canadian definitions are from Canada Motor Vehicle Safety Regulations, 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 vehicle for emergency medical care which Designated Seating Position (Canada) – any plan view
provides: A driver’s compartment; a patient compartment to position capable of accommodating a person at least as
accommodate an Emergency Medical Technician (EMT), large as a 5th percentile adult female, as defined in section
Paramedic, and two litter patients (one patient on the 100 of Schedule IV, where the overall seat configuration
primary cot and secondary patient on folding litter located and design and the vehicle design are such that the
on the squad bench) so positioned that the primary patient position is likely to be used as a seating position while
can be given intensive life-support during transit; equipment the vehicle is in motion, but does not include any plan
and supplies for emergency care at the scene as well view position of temporary or folding jump seats or other
as during transport; two-way radio communication; and, auxiliary seating accommodation.
when necessary, equipment for light rescue/extrication Final Stage Manufacturer – a person or company who
procedures. The Ambulance shall be designed and performs such manufacturing operations on an incomplete
constructed to afford safety, comfort, and avoid aggravation vehicle that it becomes a completed vehicle.
of the patient’s injury or illness. (From Federal Specification
KKK-A-1822-D). Ford Motor Company also includes within Forward Control – a vehicle configuration in which more than
its definition of ambulance any vehicle that is used for half of the engine length is rearward of the foremost point
transporting life-support equipment, for rescue operations, of the windshield base and the steering wheel hub is in the
or for non-emergency patient transfer if the engine of the forward quarter of the vehicle length.
vehicle is equipped with a “throttle kicker” device, which Gross Axle Weight Rating (GAWR) – the value specified
enables an operator to increase engine speed over normal by the vehicle manufacturer as the load-carrying capacity
idle speed when the vehicle is not moving. of a single axle system, as measured at the tire-ground
B-Pillar – is the vehicle body structure located directly interfaces.
rearward of each front door. This structure will include Gross Combination Weight Rating (GCWR) – the value
the outer panel, all inner panels or reinforcements which specified by the manufacturer as the loaded weight of a
support the door opening, the door latching system, and/or combination vehicle.
the roof structure (source: Ford Motor Company). Gross Vehicle Weight Rating (GVWR) – the value specified
Bus – a motor vehicle with motive power, except a trailer, by the manufacturer as the loaded weight of a single
designed for carrying more than 10 persons. vehicle.
Bus (Canada) – a vehicle having a designated seating H-Point – the mechanically hinged hip point of a manikin
capacity of more than 10, but does not include a trailer or a which simulated the actual pivot center of the human
vehicle imported temporarily for special purposes. torso and thigh, described in SAE Recommended Practice
Chassis Cab – an incomplete vehicle, with completed J826, “Manikins For Use in Defining Vehicle Seating
occupant compartment, that requires only the addition Accommodation,” November 1962.
of cargo-carrying, work performing, or load-bearing H-point (Canada) – the mechanically hinged hip point of
components to perform its intended function. a manikin that simulates the actual pivot centre of the
Critical Control Item – is a component or procedure which human torso and thigh, described in SAE Standard J826
may affect compliance with a federal regulation or, which APR80, Devices for Use in Defining and Measuring Vehicle
could directly affect the safe operation of the vehicle. The Seating Accomodation.
identifying symbol is an inverted delta ( ). (source: Ford Incomplete Vehicle – an assemblage consisting, as a
Motor Company) minimum, of frame and chassis structure, power train,
Cutaway Chassis (Canada) – an incomplete vehicle that has steering system, suspension system, and braking system,
the back of the cab cut out for the intended installation of a to the extent that those systems are to be part of the
structure that permits access from the driver’s area to the completed vehicle, that requires further manufacturing
back of the vehicle; (chassis tornque). operations, other than the addition of readily attachable
components such as mirrors or tire and rim assemblies,
Designated Seating Position – any plan view location or minor finishing operations, such as painting, to become
capable of accommodating a person at least as large as a a completed vehicle.
5th percentile adult female, if the overall seat configuration
and design and vehicle design is such that the position is Incomplete Vehicle (Canada) – (a) a vehicle other than
likely to be used as a seating position while the vehicle is a vehicle imported temporaraily for special purposes,
in motion, except for auxiliary seating accommodations that is capable of being driven and that concists, at a
such as temporary or folding jump seats. Any bench or minimum, of a chassis structure, power train, steering
split-bench seat in passenger car, truck, or multipurpose system, suspension system and braking system in the state
passenger vehicle with a GVWR of 10,000 pounds or less, in which those systems are to be part of the completed
having greater than 50 inches of hip room (measured vehicle, but requires further manufacturing operations to
in accordance with SAE Standard J1100(a)) shall have become a completed vehicle or (b) that is an incomplete
not less than three designated seating positions, unless trailer; (véhicule incomplet)
the seat design or vehicle design is such that the center Incomplete Vehicle Manufacturer – a person or company
position cannot be used for seating. who manufactures an incomplete vehicle by assembling
components none of which, taken separately constitute
an incomplete vehicle.

E-SERIES (May, 2003) 7 DEFINITIONS

 DEFINITIONS

Intermediate Manufacturer – a person or company, other vehicle. (source: Ford Motor Company)
than the incomplete vehicle manufacturer or the final stage School Bus – a bus that is sold or introduced in interstate
manufacturer, who performs manufacturing operations on commerce for purposes that include carrying students to
an incomplete vehicle. and from school or related events, but does not include a
Multipurpose Passenger Vehicle (MPV) – a motor vehicle bus designed and sold for operation as a common carrier
with motive power, except a trailer, designed to carry 10 in urban transportation.
persons or less which is constructed either on a truck School Bus (Canada) – a bus designed or equipped primarily
chassis or with special features for occasional off-road to carry students to and from school.
operation.
Subsequent Stage Manufacturer – is a term which means
Multipurpose Passenger Vehicle (MPV) (Canada) – a either intermediate or final stage manufacturers or both.
vehicle having a designated seating capacity of 10 or less (source: Ford Motor Company).
that is constructed either on a truck-chassis or with special
features for occasional off-road operation, but does not Trimmed Seat – a complete functional seat assembly including
include an air cushion vehicle, an all-terrain vehicle, a low- the seat pedestal, seat track, seat base frame, seat back,
speed vechicle, a golf-cart, a passenger car, a truck or a recliner mechanism, seat padding, all attaching hardware,
vehicle imported temporarily for special purposes. and the final trim material (i.e., cloth, leather, or vinyl).
(source: Ford Motor Company).
Prescribed Class (Canada) – a class of vehicle listed in
Schedule III or the class of incomplete vehicle prescribed Truck – a motor vehicle with motive power, except a trailer,
under subsection 4(1.1); (catégorie réglementaire). designed primarily for the transportation of property or
special purpose equipment.
Seating Reference Point – the manufacturer’s design
reference point which: Truck (Canada) – a vehicle designed primarily for the
transportation of property or special-purpose equipment but
(a) Establishes the rearmost normal design driving or does not include a competition vehicle, a crawler-mounted
riding position of each designated seating position vehicle, a trailer, a work vehicle, a vehicle imported
in a vehicle; temporarily for special purposes or a vehicle designed for
(b) Has coordinates established relative to the designed operation exclusively off-road; (camion).
vehicle structure; Truck-Tractor – a truck designed primarily for drawing other
(c) Simulates the position of the pivot center of the human motor vehicles and not so constructed as to carry a load
torso and thigh; and other than a part of the weight of the vehicle and the
(d) Is the reference point employed to position the two load so drawn.
dimensional templates described in SAE Recommended Truck Tractor (Canada) – a truck designed primarily for
Practice J826. “Manikins for Use in Defining Vehicle drawing other vehicles and not constructed for carrying
Seating Accommodation,” November, 1962. any load other than part of the weight of the vehicle and
Seating Reference Point (Canada) – the unique Design load drawn, and includes a vehicle designed to accept a
H-point, as defined in section 2.2.11.1 of SAE fifth-wheel coupling but does not include a crane-equipped
Recommended Practice J1100 (June 1993), that: breakdown vehicle.
(a) Establishes the rearmost normal design driving or riding Unloaded Vehicle Weight (UVW) – the weight of a vehicle
position of each designated seating position, taking into with maximum capacity of all fluids necessary for operation
account all modes of adjustment-horizontal, vertical of the vehicle, but without cargo, occupants, or accessories
and tilt-in a vehicle; that are ordinarily removed from the vehicle when it is
not in use.
(b) Has X, Y and Z coordinates, as defined in section
2.2.3 of SAE Recommended Practice J1100 (June Unloaded Vehicle Weight (Canada) – the weight of a vehicle
1993), established relative to the designed vehicle equipped with containers for the fluids necessary for the
structure; operation of the vehicle filled to their maximum capacity
but without cargo or occupants.
(c) Simulates the position of the pivot center of the human
torso and thigh; and Untrimmed Seat – the structure including the seat pedestal,
seat track, seat base frame, seat back, recliner mechanism,
(d) Is the reference point employed to position the H-point seat padding, and all attaching hardware required for a
template with the 95th percentile leg, as described functional seat assembly without the final trim material
in section 3.1 of SAE Standard J826 (June 1992), (e.g., cloth, leather, or vinyl) and trim material attaching
or, if that drafting template cannot be positioned, components. (source: Ford Motor Company)
the reference point when the seat is in its rearmost
adjustment position. Walk-In Van – is a step entry city delivery van type vehicle that
permits a person to enter the vehicle without stooping. This
Second Unit Body (SUB) – consists of the body structure definition by Ford Motor Company is based on information
and/or all the cargo carrying, work performing, and/or appearing in 41 FR 54945, published December 16,1976,
load bearing components and/or equipment installed by a and in 42 FR 34288, published July 5,1977.
subsequent stage manufacturer on an incomplete vehicle,
such that the incomplete vehicle becomes a completed Walk-In Van (Canada) – a van type of truck in which a person
having a height of 1 700 mm can enter the occupant
compartment in an upright position by a front door.

DEFINITIONS 8 E-SERIES (May, 2003)

 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 6.
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 my be noted at the conclusion of each safety standard number.

PART 101 The statements below are applicable to the following

565.4 The statement below is applicable to all incomplete incomplete vehicle types with no driver-seat:
vehicle types except the Basic (Stripped) Chassis: • Incomplete E-Series Van
This vehicle, when completed, will conform to Part 565.4, • Cutaway
Vehicle Identification Number, if the vehicle identification This vehicle, when completed will conform to Standard
number mounted on the top of the instrument panel is 101, Controls and Displays if:
not removed, altered, or modified and no actions are
taken by the subsequent stage manufacturer that would • The Seating Reference Point (see definition on page
obstruct the readability of the Vehicle Identification 8) and the seat back torso angle of the driver-seat
Number mounted on the top of the instrument panel. when completed or installed by a subsequent stage
manufacturer are located as shown in the Figure C
565.4 The statements below are applicable to the following page 32, for E-Series type vehicles.
incomplete vehicle types:
• The controls, displays, and their identifications
• E-Series Basic (Stripped) Chassis supplied by Ford Motor Company are not removed,
This vehicle, when completed, will conform to Part altered, or relocated.
565.4, Vehicle Identification Number, if: • The components, wiring, or power supply installed by
• The E-Series vehicle identification number printed on Ford Motor Company to illuminate any control, display,
the label affixed to the cover of this manual is mounted or their identification are not removed or altered so
and displayed in accordance with the requirements as to affect lighting performance.
of this Standard. • Components added to the vehicle do not obstruct
101 The statements below are applicable to the following the driver’s ability to operate or visually locate the
incomplete vehicle types when equipped with a controls, displays, and their identifications.
driver seat: Any controls, displays, and illumination added to
• Chassis Cab this vehicle must conform to the requirements of this
• Incomplete E-Series Van or Wagon Standard.
• Cutaway 101 The statement below is applicable to the following
This vehicle, when completed, will conform to Standard incomplete vehicle types:
101, Controls and Displays if: • E-Series Basic (Stripped) Chassis
• The controls, displays, and their identifications Conformity with Standard 101, Controls and Displays, is
supplied by Ford Motor Company are not removed, not substantially affected by the design of this incomplete
relocated, altered, or modified. vehicle; accordingly, Ford Motor Company makes no
• The components, wiring, and power supply installed representation as to conformity with this Standard.
by Ford Motor Company to illuminate any control,
display, or their identification are not removed or
altered so as to affect lighting performance.
• Components added to the vehicle do not obstruct
the driver’s ability to operate or visually locate the
controls, displays, and their identifications.
• The driver-seat is not replaced, relocated, or modified
other than for the addition of seat trim.
Any controls, displays, and illumination added to this
vehicle must conform to the requirements of this
Standard.

E-SERIES (May, 2003) 9 STATEMENTS OF CONFORMITY

102 The statements below are applicable to all incomplete 102 The statements below are applicable to the the
vehicle types except the Basic (Stripped) Chassis: following incomplete vehicle types:
This vehicle, when completed, will conform to Standard • E-Series Basic (Stripped) Chassis
102, Transmission Shift Lever Sequence, Star ter This vehicle, when completed, will conform to Standard
Interlock, and Transmission Braking Effect, if no 102, Transmission Shift Lever Sequence, Star ter
alterations or adjustments are made to: Interlock, and Transmission Braking Effect if:
• Automatic Transmission - the transmission, shift cable, • No alterations or adjustments are made to the
transmission outer shift lever, shift cable bracket, transmission, shift cable, transmission outer shift
vacuum tubes, vacuum pump system, brake-shift lever, shift cable bracket, vacuum tubes, vacuum
interlock system, the starter interlock system, and pump system, brake-shift interlock system, the starter
wiring circuit from the interlock switch to the power interlock system, and wiring circuit from the interlock
source. switch to the power source.
• Manual and Automatic Transmission - the cluth- • The E-Series Basic (Stripped) Chassis is equipped
ignition interlock system (if equipped), transmission with a temporary transmission gear selector indicator
shift decal, knob, or transmission indicator dial (PRNDL) which must be replaced with the cluster and
identification. transmission gear selector indicator (PRNDL) that is
If an auxiliary transmission is added to this vehicle, it shipped with the vehicle in the dunnage box and must
must conform to the requirements of this Standard. be installed and adjusted following the instructions
and specifications shown in the figure below.
If an auxiliary transmission is added to this vehicle, it
must conform to the requirements of this Standard.

1. Route the cable after the instrument cluster is installed in

[ ] ALL DIMENSIONS ARE INCHES the vehicle. Do not kink the cable. Do not bend the cable
INSTRUMENT
CLUSTER
to a radius less than 4.5 inches. Route the cable from
the cluster in a counter-clockwise direction, under the
UNLEADED FUEL
ONLY H

30
40
50
60

70
H
steering column, using the screw provided. Do not wrap
the cable around the steering column. The steering column
F 00 0 0 0 0 80
C 20

E
10

0
MPH 0 0
0 0
90 18
FRONT OF
100

shroud installation should not affect the cable routing

BRAKE

VEHICLE
SERVICE
ENGINE SOON

or function.
COLUMN SHIFT
(PRND21) LEVER
2. Pull on the cable end loop for a functional check. The
P R N D
1

3.0-3.5 LB. WEIGHT cable should operate with a similar effort as required prior
HAND TOOL
+

to routing. Then place the cable loop on the shift lever

CABLE [2.375] ± 0.25 DIA.
retainer pin.
3. Rotate the column shift lever clockwise until it bottoms
HOLE: [1.125] DIA.
out in first gear.
X [2.188] ± 0.25 DEEP
4. Rotate the column shift lever counter-clockwise 2 detents
+

SHIFT LEVER
RETAINER PIN for Overdrive “Oval D” position for 4R100 and TorqShift™
CABLE RETENTION
BRACKET
Transmissions.
STEERING 5. Install a 3 pound weight, as defined in this illustration, on
N800705 SCREW
COLUMN
TORQUE 20-29 IN.LB. the end of the column shift lever.
CABLE THUMB WHEEL
6. Center the pointer in the middle of the “Oval D” position by
(PRNDL) ADJUSTMENT TOLERANCE rotating the thumb wheel.
LEFT LIMIT TARGET RIGHT LIMIT 7. Remove the 3 pound weight. The pointer must be within
the tolerances as defined in this illustration.
8. After the steering column shrouds are installed, the
4R100, TorqShift™ TRANSMISSIONS transmission gear selector indicator (PRNDL) system must
be checked for proper operation.

INSTALLATION OF GEAR SELECTOR INDICATOR (PRNDL) FOR E-SERIES BASIC (STRIPPED) CHASSIS

STATEMENTS OF CONFORMITY 10 E-SERIES (May, 2003)

103 The statement below is applicable to all incomplete 105 The statements below are applicable to the E-Series
vehicle types except the Basic (Stripped) Chassis: cutaway when equipped with the School Bus Prep
This vehicle, when completed, will conform to Standard package and completed as a school bus:
103, Windshield Defrosting and Defogging Systems, This vehicle when completed, will conform to Standard
if no alterations or adjustments are made to heater 105, Hydraulic and Electric Brake Systems, if:
and blower assemblies, ducting, operating controls, • No alterations, modifications, or replacements are
electrical circuit from the blower assembly to the power made to the following:
source, windshield, coolant hoses from the radiator or
engine to the heater, and if no obstructions are added – Service or parking brake system
that restrict or otherwise redirect the air flow from the – Antilock brake system
defroster outlets to the windshield. – Vacuum system
103 The statement below is applicable to the following – Wheels and tires
incomplete vehicle types: – Brake system indicator lamp and wiring
• E-Series Basic (Stripped) Chassis
– Brake system reservoir labeling
Conformity with Standard 103, Windshield Defrosting
– Suspension ride height or spring rate
and Defogging Systems, is not substantially affected
by the design of this incomplete vehicle; accordingly, – Hydro-Boost system
Ford Motor Company makes no representation as to – Power Steering pump and lines if used with
conformity with this Standard. Hydro-boost
104 The statement below Is applicable to all Incomplete – Engine belt drive system
vehicle types except the Basic (Stripped) Chassis: – Wheelbase
This vehicle when completed, will conform to Standard • The E-350 SRW Unloaded Vehicle Weight (see
104, Windshield Wiping and Washing Systems, if no definition on page 8) is not less than the minimum
alterations are made to the windshield, the windshield value of 2540 kg [5600 lb].
wiping and washing system, including the electrical
circuit from the windshield wiping and washing motors • The E-350/450 DRW minimum UVW must be at least
to the power source, and if no obstructions are added the weights shown on the following chart:
that restrict or otherwise redirect fluid flow from the
washer nozzles to the windshield. MINIMUM UNLOADED VEHICLE WEIGHT (UVW)
KILOGRAM [POUND]
104 The statement below Is applicable to the following
incomplete vehicle types: E-350 DRW 3673 [8100]
• E-Series Basic (Stripped) Chassis E-450 DRW 4128 [9100]
Conformity with Standard 104. Windshield Wiping
and Washing Systems, is not substantially affected • The maximum GAWRs and GVWR, as identified on
by the design of this incomplete vehicle; accordingly, the cover of this document, are not exceeded.
Ford Motor Company makes no representation as to
conformity with this Standard. • The transverse center of gravity is less than 50.8
mm [2.0 in] either side of the vehicle centerline for
105 INFORMATION E-350 only.
Incomplete vehicle weight and dimensional information • Service or parking brake pedal assembly operation
required for center of gravity calculations are available must not be restricted by any alteration or added
in the Ford Source Book. See your local Ford Dealer components.
and refer to appropriate model year and specific vehicle
for required information. • The horizontal and vertical center of gravity, of the
completed vehicle at Unloaded Vehicle Weight,
Abbreviation definitions and a vehicle diagram to assist is within the minimum and maximum locations as
with the equations for the Standard 105 segment are defined in the following chart:
shown on page 14.
NOTE: 105 is an example of a standard with conformity
statements that contain minimum requirements for CENTER OF GRAVITY LOCATION DIMENSIONS FOR
completed vehicle Unloaded Vehicle Weight (UVW, see INCOMPLETE E-SERIES CUTAWAY WITH
SCHOOL BUS PREP PACKAGE
definition on page 8). Maximum UVW requirements
are also found in various sections of this manual (see E-350 E-350 E-450
especially Standards 212/219 and 301 and related table, LOCATION SRW DRW DRW
Table A). Completed vehicles must meet UVW limits mm[in] mm[in] mm[in]
imposed by all applicable requirements. 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 at a point midway between
the centerlines of the front and rear axles.
(2) Measured rearward from the centerline of the front axle.

E-SERIES (May, 2003) 11 STATEMENTS OF CONFORMITY

105 The statements below are applicable to the following • The horizontal center of gravity for the SUB is:
incomplete vehicle types if the GVWR is between – At or forward of the rear axle centerline. The vertical
3500 kg [7716 lb] and 3629 kg [8000 lb]: center of gravity for the completed vehicle at
• Incomplete E-Series Van or Wagon Unloaded Vehicle Weight + 400 lb passenger load
This vehicle, when completed, will conform to Standard CGv (Equation A) must not exceed 36.0 inches,
105, Hydraulic and Electric Brake Systems, if: when measured from the ground.
• No alterations, modifications, or replacements are – Behind the rear axle centerline. The vertical center
made to the following: of gravity for the completed vehicle at Unloaded
Vehicle Weight + 400 lb passenger load must fall
– Service or parking brake system
within the appropriate range determined from
– Antilock brake system Table G, page 16. The value of CGh (Equation B),
– Vacuum system which approximates the horizontal center of gravity
– Wheels and tires of the completed vehicle, is used in Table G, to
determine the vertical center of gravity limits for the
– Brake system indicator lamp and wiring completed vehicle. The value CGV (Equation A),
– Brake system reservoir labeling which approximates the vertical center of gravity
– Suspension ride height or spring rate of the completed vehicle, must fall within the
appropriate range determined from Table G.
– Wheelbase
• Any removal of a Ford body or chassis 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 EQUATION A
the vehicle weight at Unloaded Vehicle Weight + 400 CGvbWb + CGvc Wc + 25P
lb passenger load. CGv =
• The service or parking brake pedal assembly Wt
operation is not restricted by any alteration or added
components.
EQUATION B
• The horizontal center of gravity of the Second Unit

(Wrb + Wrc + ( ) )x WB
Body (SUB) is rearward of Lmin† for the appropriate P x CGhp
vehicle description in the table below. Lmin does
not apply to a SUB of 120 lb or less when installed CGh = WB
rearward of the front seats and forward of the Wt
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). 105 (Continued Next Page)

HORIZONTAL CENTER OF GRAVITY

FORWARD LIMIT TABLE
Wheelbase Lmin
Vehicle Millimeter [inch] Millimeter [inch]
E-250 3505 [138] 1524 [60]

† Lmin = the minimum horizontal center of gravity of the

SUB measured in inches rearward from the centerline
of the front axle.

STATEMENTS OF CONFORMITY 12 E-SERIES (May, 2003)

105 (Continued) The horizontal center of gravity for the SUB is:
– At or forward of the rear axle centerline. The vertical
105 The statements below are applicable to the following center of gravity for the completed vehicle at GVWR
incomplete vehicle types except when completed as CGv (Equation C) must not exceed 48.0 inches
a school bus, and if the GVWR is between 3629 kg when measured from the ground.
[8000 lb] and 6373 kg [14,050 lb] inclusive: – Behind the rear axle centerline. The vertical center
• Incomplete E-Series Van or Wagon of gravity for the completed vehicle at GVWR must
• E-Series Cutaway and Chassis Cab fall within the appropriate range determined from
• E-Series Basic (Stripped) Chassis Table G page 16. The value of CGh (Equation D),
which approximates the horizontal center of gravity
This vehicle, when completed, will conform to Standard of the completed vehicle, is used in Table G to
105, Hydraulic and Electric Brake Systems, if: determine the vertical center of gravity limits for
• No alterations, modifications, or replacements are the completed vehicle. The value of CGv (Equation
made to the following: C) which approximates the ver tical center of
– Service or parking brake system gravity of the completed vehicle must fall within the
appropriate range determined from Table G.
– Antilock brake system
– Vacuum system
– Wheels and tires
– Brake system indicator lamp and wiring
– Brake system reservoir labeling EQUATION C
– Suspension ride height or spring rate
– Hydro-boost system
– Power steering pump and lines if used with Hydro- CGv =
CGvbWb + CGvc Wc + Wl( ) + 25P
boost GVWR
– Engine belt drive system
– Wheelbase EQUATION D
• No additional sound deadener or rust proofing

(Wrb + Wrc +( ) )
material, that may be applied to the vehicle, can P x CGhp
interfere with proper parking brake cable function. WB + Wrl x WB
• No part of add on equipment, i.e. toolboxes, flat
CGh =
GVWR
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 PASSENGER LOAD TABLE
• E-Series Cutaways/Chassis Cab and Basic (Stripped)
Chassis vehicles conform to the minimum SUB GVWR [lb] P [lb]
weights found in Table E, page 15. 0 - 7716 397
• The maximum GAWRs and GVWR, as identified on 7717 - 10,000 400
the cover of this document, are not exceeded with 10,001 - 19,000 500
the vehicle weight at Unloaded Vehicle Weight +
Passenger Load (P). (See E-Series Passenger Load
Table on this page.)
105 (Continued on Page 16)
• The service or parking brake pedal assembly
operation is not restricted by any alteration or added
components.
• The SUB horizontal center of gravity must be at or
forward of the rear axle centerline for the following
vehicles:
- E-250/350/450 Basic (Stripped) Chassis
- E-350 Super Duty Cutaway (DRW)
- E-450 Super Duty Cutaway
- E-350/450 Chassis Cab

E-SERIES (May, 2003) 13 STATEMENTS OF CONFORMITY

 FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES

L† = Horizontal distance in inches between the SUB Wc = Weight of the vehicle (chassis and cab) (fuel
center of gravity and the of the front axle. tanks full) [pounds]. Including option weight.
P = Passenger load (See E-Series Passenger Load WB = Vehicle wheelbase [inches].
Table page 13). Wt = Total unladen weight = (Wb + Wc + P)
CGv = Vertical distance from the ground to the center of GVWR = Gross Vehicle Weight Rating of the vehicle
gravity [inches] of the completed vehicle. [pounds].
CGh = Horizontal distance from of the front wheels to WI ‡ = Remaining cargo capacity [pounds].
completed vehicle center of gravity [inches].
Where: Wl = GVWR - (Wb + Wc + P)
CGvb = Vertical distance from the ground to the center of
gravity of the SUB and/or permanently attached Wrl‡ = Weight of the remaining cargo capacity on the
added equipment [inches]. rear wheels [pounds].
CGvc = Vertical distance from the ground to the center (CGhI)WI
of gravity of the chassis [inches] (including WrI =
WB
cab if original equipment). (Taken from Table
F, page 16). CG hI ‡ = Horizontal distance from the of the front
CGhp = Horizontal distance from the of the front wheels to the cargo center of gravity [inches]
wheels to the P [inches] (passenger load) (taken (taken from Table C page 16). For many common
from Table D, page 16). vehicles, the CGhI is not given in the table, then
it may be estimated as the distance from the
Wb = Weight of the SUB and/or permanently attached of the front wheel to the horizontal midpoint
added equipment [pounds]. of the cargo area.
Wrb = Weight at the rear wheels of the SUB SUB = A Second Unit Body consists of the body
and/or permanently attached added equipment structure and/or all the cargo carrying, work
[pounds]. performing, and/or load bearing components
Wrc = Weight at the rear wheels of the vehicle (chassis and/or equipment installed by a subsequent
and cab) (fuel tanks full) [pounds]. Including stage manufacturer on an incomplete vehicle,
option weight. such that the incomplete vehicle becomes a
completed vehicle.
† Required for <8000 lb. GVWR calculations only. ‡ Required for ≥8000 lb. GVWR calculations only.

WB

L CG hl

CG h CG OF CHASSIS
CG hp CG OF COMPLETED VEHICLE
CG OF SUB

SUB

P
CG vb

CG v

CG vc

Wc Wt GVWR
W rl W rb Wb

W rc Wl
IVM0001

STATEMENTS OF CONFORMITY 14 E-SERIES (May, 2003)

 TABLE A
Maximum Unloaded Vehicle Weight (UVW) for Incomplete Gas/Diesel Vehicles once completed (2)(3)
This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR
WHEELBASE
Millimeter MAXIMUM
MODELS [inch] UNLOADED VEHICLE WEIGHTS - Kilogram [pound]
INCOMPLETE E-SERIES VEHICLES
E-150 Reg. Van 3505 [138] 2699 [5950](1)
E-150 Reg. Wagon 3505 [138] 2699 [5950](1)
E-250 Reg. and Ext. Van 3505 [138] 3130 [6900]
E-350 Reg. and Ext. Van 3505 [138] 3583 [7900]
E-350 Reg. and Ext. Wagon 3505 [138] 3583 [7900]
E-350 Cutaway 3505 [138] 3856 [8500]
E-350 Basic (Stripped) Chassis SRW 3505 [138] 3946 [8700]
E-350 Basic (Stripped) Chassis DRW 3505 [138] 3946 [8700]
E-350 Basic (Stripped) Chassis SRW 4013 [158] 3946 [8700]
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 unloaded vehicle weight values shown in this Table are limits for purposes of F/CMVSS conformity only. See Emission
Certification information on page 56 for possible additional weight restrictions to meet emission requirements.
(3) Also applies to NGV vehicles for Standards 212/219 only.

TABLE E
MINIMUM SUB WEIGHT
Minimum unloaded vehicle weight for cutaways completed as
school buses defined in 105 requirements on page 11.
Kilogram
MODELS [Pound]
E-350 Cutaway/Chassis Cab DRW 204
3505mm [138 in] WB [450]
E-350 Cutaway/Chassis Cab DRW 238
4013mm [158 in] WB [525]
E-350 Cutaway/Chassis Cab DRW 238
4470mm [176 in] WB [525]
E-450 Cutaway/Chassis Cab DRW 238
4013mm [158 in] WB [525]
E-450 Cutaway/Chassis Cab DRW 238
4470mm [176 in] WB [525]
E-250 Basic (Stripped) Chassis SRW 771
[1700]
E-350 Basic (Stripped) Chassis DRW 862
All WB [1900]
E-450 Basic (Stripped) Chassis DRW 998
All WB [2200]

E-SERIES (May, 2003) 15 STATEMENTS OF CONFORMITY

 TABLE C TABLE F
CGhl = Horizontal distance from front axle cargo CG: CGVC = Vertical distance ground to chassis CG
(Dimensions are inches)
Model WB (in) CGhl (in)†
E-Series: E-150 & E-250 Van <8000 lb GVWR = 28.5
Regular Van 138 116 E-250/350 SRW Van or Wagon >8000 lb GVWR = 32.0
†Extended Van or Extended Wagon 138 126 E-350 Cutaway/Chassis Cab = 28.0
†Cutaway (SRW) 138 121 E-450 Cutaway/Chassis Cab = 26.5
(DRW) 138 127 E-250 SRW Basic (Stripped) Chassis = 25.0
†Comm. Cab/Box Partition (DRW) 158 134 E-350/450 Basic (Stripped) Chassis = 26.5
†RV (DRW) 158 138
†Comm. No Partition (DRW) 158 143
†RV (DRW) 176 153
†Comm. (DRW) 176 160
† If CGhI is not given in the table or if the location of your cargo is
not in the normal cargo area, then your CGhI may be estimated
as the distance from the of the front wheel to the horizontal
midpoint of the cargo area.

TABLE D
CGhp = Horizontal distance from front wheel to
Passenger Load. (Dimensions are inches)
All E-Series† 48.5
† Except the E-Series Basic (Stripped) Chassis where the distance
from the of the front axle to the H point of the driver must
be measured.

TABLE G
CGv = Vertical distance from the ground to the completed vehicle center of gravity [inch].
GVWR <8000 lb Use equation A & B, page 12
Place the CGh of the vehicle (from equation B) into the appropriate equations below to determine the allowable range
of the CGv. If the actual CGv (from equation A) is within the range calculated, the center of gravity location is acceptable.

Equation for CGv Range

Model WB Upper Limit Lower Limit
E-150 138 CGv = 1.39 x CGh - 46.9 1.39 x CGh - 58.7
E-250 7900 lb GVWR 138 CGv = 1.39 x CGh - 47.1 1.39 x CGh - 59.0

GVWR > 8000 lb to <19000 lb Use equation C & D, page 13

Place the CGh of the vehicle (from equation D) into the appropriate equations below to determine the allowable range
of the CGv. If the actual CGv (from equation C) is within the range calculated, the center of gravity location is acceptable.

Equation for CGv Range

Model WB Upper Limit Lower Limit
E-250 8600 lb GVWR 138 CGv = 1.27 x CGh - 59.0 1.27 x CGh - 77.5
E-350 (SRW) 138 CGv = 1.27 x CGh - 60.0 1.27 x CGh - 80.0
<9600 Ib GVWR 158 CGv = 1.27 x CGh - 69.5 1.27 x CGh - 90.7

STATEMENTS OF CONFORMITY 16 E-SERIES (May, 2003)

106 The statement below is applicable to all incomplete 108 The statement below is applicable to the following
vehicle types: vehicle with a GVWR of 4536 kg [10,000 lb] or less and
This vehicle, when completed, will conform to Standard a vehicle width less than 2032 mm [80.00 in]:
106, Brake Hoses, if the brake hose assemblies supplied • Chassis Cab
by Ford Motor Company are not removed, relocated, • Cutaway
altered, or modified and if no brake hose assemblies This vehicle, when completed, will conform to Standard
are added. 108, Lamps, Reflective Devices, and Associated
108 In addition to the statements pertaining to particular Equipment. If a Center High Mounted Stop Lamp
incomplete vehicle types which follow on pages (CHMSL) is installed on a Cutaway or if the Chassis
18 and 19, the statements immediately below, Cab CHMSL, when provided, is obstructed from the
concerning Standard 108 Lamps, Reflective Devices, rear of the completed vehicle it must be replaced with a
and Associated Equipment are applicable to all CHMSL that meets all the requirements of this standard
incomplete vehicle types except the Basic (Stripped) and is connected to the electrical power source as
Chassis: provided by Ford Motor Company. See the figure below
No additional components may be added to the for circuit location.
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, are not substantially affected
by the design of this incomplete vehicle; accordingly,
Ford Motor Company makes no representation as to
conformity with this Standard.

THE “CHMSL” ELECTRICAL CONNECTION FOR

AN ECONOLINE BASIC (STRIPPED) CHASSIS IS
PROVIDED IN A DETAILED SCHEMATIC WHICH
IS PACKAGED WITH THE BODY BUILDER
ELECTRICAL CONNECTORS.

TO INSTALL "CHMSL"
UNWRAP TAPE FROM
HARNESS IN THIS AREA
AND REMOVE JUMPER
CONNECTION TO EXPOSE
THE "CHMSL CONNECTOR".

FRONT OF
VEHICLE

E-SERIES CUTAWAY AND CHASSIS CAB

CENTER HIGH-MOUNTED STOP LAMP (CHMSL)

ELECTRICAL CONNECTOR LOCATION

E-SERIES (May, 2003) 17 STATEMENTS OF CONFORMITY

 108 The statements below are applicable to the following
TABLE K incomplete vehicle types:
(Reference Standard 108)
• Chassis Cab
E-Series • Cutaway
Completed
As: Truck, This vehicle, when completed, will conform to Standard
MPV, Bus or 108, Lamps, Reflective Devices, and Associated
School Bus Equipment, if all the required lighting equipment as
indicated in Table K on this page (identified by the codes

2032 mm [80 in]

Width 2032 mm
Width less than
D, R and S) is designed and installed in accordance with

[80 in] or more

the requirements of Standard 108 and the directions
contained in this statement. Additionally, if the completed
vehicle overall length is 9.14 meters [30 feet] or more,
intermediate side marker lamps and reflex reflectors
(not supplied by Ford Motor Company) are also required
for compliance with Standard 108.
Headlamps S S
Tail Lamps R/D R/D The items of equipment which are supplied by Ford
Motor Company (identified by the code S in Table K,
Stop Lamps R/D R/D on this page) are designed and installed to conform to
Center High Mounted all the requirements of Standard 108. The completed
Stop Lamp (CHMSL) R N vehicle will conform with these components if the
License Plate Lamps R/D R/D subsequent stage manufacturer does not remove,
Reflex Reflectors – Side Front S S relocate, alter, or modify such equipment or modify the
– SideRear R R power supply or wiring to such equipment, and does
not complete the body in such a configuration as to
– Rear R R
impair the visibility and conformity to the photometric
Side Marker Lamps – Front S S requirements of the installed lamps and reflective
– Rear R R devices.
Back-Up Lamps R/D R/D Specific requirements for lighting and associated
Turn Signal Lamps – Front S S equipment are listed by incomplete vehicle type in Table
– Rear R/D R/D K on this page.
Turn Signal Operating Unit S S Lamps, reflective devices, and associated equipment
Turn Signal Flasher (2) S S necessary to complete the vehicle from an incomplete
Veh. Haz. Wrng. Oper. Unit S S vehicle must conform to the equipment, locations,
special wiring, visibility, photometric, and performance
Veh. Haz. Wrng. Flasher S S
requirements of Standard 108 and to the applicable
Identification Lamps – Front N R SAE standards or recommended practices referenced
– Rear N R or sub-referenced in this Standard.
Clearance Lamps – Front N R(1) All electrical equipment added to the vehicle by
– Rear N R subsequent stage manufacturers must conform to the
Parking Lamps R N wiring practices set forth in the Electrical Wiring Section
School Bus Lamps and Switches R R of the Ford Truck Body Builders’ Layout Book.
(School Buses only) 108 The statements below are applicable to the following
S Required on completed vehicle and supplied with the incomplete vehicle types:
incomplete vehicle • Incomplete E-Series Van or Wagon
R Required on completed vehicle and not supplied with the This vehicle, when completed, will conform to Standard
incomplete vehicle
108, Lamps, Reflective Devices, and Associated
N Not required for completed vehicle
Equipment, if the subsequent stage manufacturer
D Required on completed vehicle and available as an option does not:
(either on vehicle or shipped in dunnage).
• Remove, alter, replace, or relocate the lighting
(1) If a second unit body width is greater than 2032 mm [80 in]
or higher than the cutaway or chassis cab body, additional equipment installed on the incomplete vehicle
clearance lamps may be required that comply with this • Modify the power supply or wiring to such equipment
standard.
• Add any additional external lighting equipment
(2) Designed for two turn signal lamps per vehicle side (one front
and rear). If additional lamps are required, replace the turn • Increase the overall width of the vehicle beyond that
signal flasher with one having the correct lamp load rating of the incomplete vehicle
• Complete, modify, or add components to the vehicle
in such a manner as to impair the visibility and
conformity to the photometric requirements of the
installed lamps and reflective devices

108 (Continued Next Page)

STATEMENTS OF CONFORMITY 18 E-SERIES (May, 2003)

108 (Continued) 111 The statements below are applicable to the incomplete
E-Series Van with no driver-seat when equipped with
108 The statement below is applicable to the E-Series a convex mirror on the passenger-side:
Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard
Conformity with Standard 108, Lamps, Reflective 111, Rearview Mirrors, if:
Devices, and Associated Equipment, is not substantially • The mirrors and their mounts as supplied by Ford
affected by the design of this incomplete vehicle; Motor Company, are not removed, relocated, replaced,
accordingly, Ford Motor Company makes no rep- or altered.
resentation as to conformity with this standard. However,
Ford Motor Company does represent that the items • No structural modifications are made to the body
of lighting equipment, when provided in the E-Series which would affect the stability of the mirror mounts.
dunnage box attached to the chassis, are designed to • The Seating Reference Point (see definition on
conform to the requirements of Standard 108. page 8) and the seat back torso angle of the driver-
seat installed or completed by the subsequent stage
108 Canadian Requirements:
manufacturer are located as shown in Figure C
The preceding statements for Standard 108 are page 32 corresponding to the particular incomplete
appropriate compliance representations for CMVSS vehicle type.
108, Lighting, and CMVSS 108.1, Headlamps, if this
• Any modifications or additions made to this incomplete
vehicle is manufactured for sale or use in Canada,
vehicle do not adversely affect the driver’s view to
provided:
the rear in the outside mirrors along both sides of
• No component of the Daytime Running Lamp (DRL) the vehicle.
system is removed, relocated, or modified.
If any alteration blocks the rear field of view through the
110 U.S. Requirements: inside mirror, Standard 111 may require that the vehicle
The statement below is applicable to all incomplete have a flat glass on the passenger side.
vehicles with a GVWR of 4536 kg [10,000 lbs] or less 111 The statement below is applicable to the following
with a completion date starting 9/01/03: incomplete vehicle types when not equipped with
This incomplete vehicle does not comply to FMVSS outside mirrors:
110. In order to comply, the final stage manufacturer • Chassis Cab
20 IL

must affix a tire placard as specified in paragraph S4.3

04

• Cutaway
R, NT

of FMVSS 110. The decal must be affixed to the B-Pillar. • E-Series Basic (Stripped) Chassis
See below for placard content and note color and format
BE U

requirements in S4.3. • Incomplete E-Series Van

EM ED

Conformity with Standard 111, Rearview Mirrors, is not

TIRE AND LOAD INFORMATION substantially affected by the design of this incomplete
PT LAY

SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION vehicle; accordingly, Ford Motor Company makes no
representation as to conformity with this Standard.
SE DE

The combined weight of occupants and cargo should never exceed XXX kg or XXX lbs.
111 The statements below are applicable to the Cutaway
SEATING CAPACITY TOTAL : 5 FRONT: 2 REAR: 3 when equipped with outside mirrors:
ORIGINAL TIRE SIZE COLD TIRE INFLATION PRESSURE Conformity with the stability requirements of Standard
FRONT P195 / 70R14
111, Rearview Mirrors, is not substantially affected
FRONT 200KPA, 29PSI
REAR P195 / 70R14 REAR 200KPA, 29PSI
by the design of this incomplete vehicle; accordingly
COMPACT TIRE SIZE COLD TIRE INFLATION PRESSURE Ford Motor Company makes no representation as to
T125/70D15 420KPA, 60PSI
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:
111 The statements below are applicable to the following • The outside mirrors and their mounts, as supplied
incomplete vehicle types when equipped with a driver by Ford Motor Company, are installed in accordance
seat (including untrimmed seat) and a convex mirror with the instructions that accompany them and they
on the passenger-side: are not relocated, replaced, or altered.
• Incomplete E-Series Van or Wagon • The Cutaway with the School Bus Prep Package is
This vehicle, when completed, will conform to Standard completed as a school bus and any outside mirrors
111, Rearview Mirrors, if: (not provided by Ford Motor Company) are installed
• The mirrors and their mounts as supplied by Ford in conformity with the requirements of Standard 111
Motor Company are not removed, relocated, replaced, for school buses.
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.

E-SERIES (May, 2003) 19 STATEMENTS OF CONFORMITY

111 The statements below are applicable to the following 116 The statement below is applicable to all incomplete
incomplete vehicle types when equipped with a flat vehicle types:
glass mirror on the passenger-side: This vehicle, when completed, will conform to Standard
• Chassis Cab 116, Motor Vehicle Brake Fluids, so long as any
• Incomplete E-Series Van brake fluid added or replaced conforms to the DOT 3
This vehicle, when completed, will conform to Standard specifications of the standard and contaminants are not
111, Rearview Mirrors, if: introduced into the hydraulic brake system.
• The mirrors and their mounts as supplied by Ford 118 The statement below is applicable to all incomplete
Motor Company are not removed, relocated, replaced, vehicle types not equipped with power windows when
or altered. completed as either a MPV or a Truck with a GVWR of
4536 kg [10,000 lb] or less:
• No structural modifications are made to the body
which would affect the stability of the mirror mounts. Conformity with Standard 118, Power Operated
Window, Partition, and Roof Panel Systems, is not
• Any modifications or additions made to the incomplete substantially affected by the design of this incomplete
vehicle must not adversely affect the driver’s view vehicle; accordingly, Ford Motor Company makes no
to the rear in the outside mirrors along both sides representation as to conformity with this Standard. If any
of the vehicle. power operated window, partition, or roof panel systems
113 The statement below is applicable to all incomplete are installed by subsequent stage manufacturers, they
vehicle types except the Basic (Stripped) Chassis: must conform to the requirements of Standard 118.
This vehicle, when completed, will conform to Standard 118 The statement below is applicable to all incomplete
113, Hood Latch Systems, if the hood latch system vehicle types equipped with power windows when
as provided by Ford Motor Company is not removed completed as either a MPV or a Truck with a GVWR of
or altered. 4536 kg [10,000 lb] or less:
113 The statement below is applicable to the following This vehicle, when completed, will conform to Standard
incomplete vehicle types: 118, Power Operated Window, Partition, and Roof Panel
• E-Series Basic (Stripped) Chassis Systems, if the power operated windows, motors, wiring,
and key and switch activation systems, where provided
Conformity with Standard 113, Hood Latch Systems, is
by Ford Motor Company, are not removed, relocated,
not substantially affected by the design of this incomplete
altered, or modified in any way. If additional power
vehicle; accordingly Ford Motor Company makes no
operated window, partition, or roof panel systems are
representation as to conformity with this Standard.
installed by subsequent stage manufacturers, they must
114 The statements below are applicable to all incomplete conform to the requirements of Standard 118.
vehicle types except the Basic (Stripped) Chassis
119 The statement below is applicable to all incomplete
when completed as either a MPV or a Truck with a
vehicle types:
GVWR of 4536 kg [10,000 lb] or less:
All tires supplied by Ford Motor Company are in full
This vehicle, when completed, will conform to Standard
conformity with Standard 119, New Pneumatic Tires for
114, Theft Protection, if the following components, to
Vehicles Other than Passenger Cars.
the extent provided by Ford Motor Company, are not
removed, relocated, altered, or modified in any way: If additional tires are installed or the existing tires are
replaced by subsequent stage manufacturers, they must
• Steering column locking mechanism system
conform to the requirements of Standard 119.
• Ignition key/transmission shift interlock locking
system 120 The statement below is applicable to all incomplete
vehicles except for the Basic (Stripped) Chassis:
• Ignition key-locking system
This vehicle, when completed, will conform to the tire
• Key warning buzzer system and rim selection requirements of Standard 120, Tire
If any of the above components are added to the Selection and Rims for Motor Vehicles Other Than
vehicle they must conform to the requirements of this Passenger Cars, if the tire and rim assemblies and the
Standard. Incomplete Vehicle Label that is affixed to the vehicle
114 The statement below is applicable to the following are not removed, altered, or replaced.
incomplete vehicle types: 120 The statements below are applicable to the following
• E-Series Basic (Stripped) Chassis incomplete vehicle types:
The Basic (Stripped) Chassis is designed by Ford • E-Series Basic (Stripped) Chassis
Motor Company to be completed as a walk-in van type This vehicle, when completed, will conform to the tire
vehicle. Walk-in vans are exempt from the requirements and rim selection requirements of Standard 120, Tire
of Standard 114, Theft Protection. See walk-in van Selection and Rims for Motor Vehicles Other Than
definition, on page 8. Passenger Cars, if:
115 Canadian Requirements: • The tire and rim assemblies, are not removed, altered,
The statements for Part 565.4 are appropriate or replaced.
compliance representations for CMVSS 115, Vehicle • The final stage manufacturer must, in accordance
Identification Number, if this incomplete vehicle was with the requirements of Standard 120 and Part
manufactured for sale or use in Canada. 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.

STATEMENTS OF CONFORMITY 20 E-SERIES (May, 2003)

124 The statements below are applicable to all incomplete 135 The statements below are applicable to the following
vehicle types: incomplete vehicle types if the GVWR is 3500 kg
This vehicle, when completed, will conform to Standard [7,716 lb] or less:
124, Accelerator Control Systems, if: • Incomplete E-Series Van or Wagon
• No alterations are made to the accelerator control rod, This vehicle, when completed, will conform to Standard
bellcranks, cables, springs, guides, accelerator pedal, 135, Light Vehicle Brake Systems, if:
mounting hardware, adjustable pedal mechanism, or • No alterations, modifications, or replacements are
other components of the accelerator control system made to the following:
as installed by Ford Motor Company.
– Service or parking brake system
• No equipment is added or existing equipment modified
– Antilock brake system
which would restrict operation of the accelerator
control system. – Vacuum system
• Vehicles equipped with electronically controlled 6.0L – Wheels and tires
Dl Turbo Diesel have no alterations made to the – Brake system indicator lamp and wiring
Pedal Position Sensor and all associated hardware – Brake system reservoir labeling
and wiring. See the figure below for component
identification. – Suspension ride height or spring rate
– Wheelbase
• Any removal of a Ford body or chassis 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 Weight + 400
lb passenger load.
• The service or parking brake pedal assembly
operation is not restricted by any alteration or added
components.
• The horizontal center of gravity of the Second Unit
Body (SUB) is rearward of Lmin† for the appropriate
vehicle description in the table below. Lmin does
not apply to a SUB of 120 lb or less when installed
rearward of the 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).

HORIZONTAL CENTER OF GRAVITY

FORWARD LIMIT TABLE
Wheelbase Lmin
Vehicle Millimeter [inch] Millimeter [inch]
ELECTRONIC ACCELERATOR CONTROL E-150 3505 [138] 1473 [58]
E-250 3505 [138] 1524 [60]

131 The statement below is applicable to the Cutaway

when equipped with the School Bus Prep Package
and completed as a school bus:
Conformity with Standard 131, School Bus Pedestrian
Safety Devices, is not substantially affected by the design
of this incomplete vehicle. Accordingly, Ford Motor
Company makes no representation as to conformity
with this Standard.

†Lmin = the minimum horizontal center of gravity of the SUB

measured in inches rearward from the centerline of the front axle.

E-SERIES (May, 2003) 21 STATEMENTS OF CONFORMITY

 • The horizontal center of gravity for the SUB is: If any of the above mentioned components (including
– At or forward of the rear axle centerline. The vertical front seats) are added to the incomplete vehicle by a
center of gravity for the completed vehicle at subsequent stage manufacturer, these components
Unloaded Vehicle Weight + 397 lb passenger load must conform to the requirements of Standard 201
CGv (Equation A) must not exceed 36.0 inches, where applicable. When front seats are installed on an
when measured from the ground. Incomplete E-Series Van or Cutaway the installed seat
must be located within the dimensional specifications
– Behind the rear axle centerline. The vertical center for the Seating Reference Point and the torso angle as
of gravity for the completed vehicle at Unloaded specified in Figure C page 32.
Vehicle Weight + 400 lb passenger load must fall
within the appropriate range determined from Because conformity of a completed vehicle to the seat
Table G, page 16. The value of CGh (Equation B), back requirements of this standard is dependent upon
which approximates the horizontal center of gravity the location of a seat installed by a subsequent stage
of the completed vehicle, is used in Table G, to manufacturer to the rear of another seat, Ford makes
determine the vertical center of gravity limits for the no representation as to compliance of a completed
completed vehicle. The value CGV (Equation A), vehicle to the seat back requirements if such a seat
which approximates the vertical center of gravity is installed.
of the completed vehicle, must fall within the If a vehicle is equipped with a Passenger Side Air Bag
appropriate range determined from Table G. Delete Option a RH passenger seat should never be
installed. If such a seat is installed Ford makes no
representation as to the compliance of the completed
vehicle to Standard 201.
EQUATION A 201 The statement below is applicable to the following
CGvbWb + CGvc Wc + 25P incomplete vehicle types if the GVWR is 4536 kg
CGv = [10,000 lb] or less:
Wt • E-Series Basic (Stripped) Chassis
Conformity with Standard 201, Occupant Protection in
Interior Impact, is not substantially affected by the design
EQUATION B of this incomplete vehicle; accordingly, Ford Motor
Company makes no representation as to conformity

(W + Wrc + ( ) )x WB
P x CGhp with this standard.
CGh = rb WB 201U U.S. Requirements (Section S6):
Wt The statements below are applicable to incomplete
vehicles with a GVWR of 4536 kg [10,000 lbs] or less,
excluding buses with a GVWR more than 3860 kg
[8510 lbs] and the Basic (Stripped) Chassis completed
201 The statements below are applicable to incomplete as a walk-in van type truck (which are exempt from
vehicles with a GVWR of 4536 kg [10,000 lb] or less, the requirement):
but excluding the Basic (Stripped) Chassis:
This vehicle when completed, will conform to Standard
This vehicle, when completed, will conform to Standard 201U, Occupant Protection in Interior Impact - Upper
201, Occupant Protection in Interior Impact, (excluding Interior head Impact Protection, if the following components
US Requirements Section S6 addressed separately) if as provided by Ford Motor Company, are not removed,
the following components, as provided by Ford Motor relocated, altered, modified or additions added to the:
Company, are not removed, relocated, altered, or
modified in any way: • A, B, Rear, or other Pillar and Trim, and Assist
Handles
• Instrument panel
• Seat Belt ‘D’-Rings/Adjusters and ‘D’-Ring Covers
• Interior compartment doors
• Front or Rear Header and Trim
• Sun visors
• Side Rails and Trim
• Arm rests
• Upper Roof and Trim
Seat backs of front seats installed by Ford Motor
Company are designed to meet the seat back If any of the above components are added to the
requirements of Standard 201. The seat mounted incomplete vehicle by a subsequent stage manufacturer,
armrest on an untrimmed front seat must be completed these components must conform to the requirements of
so as to meet the requirements of this Standard. Standard 201U where applicable.

STATEMENTS OF CONFORMITY 22 E-SERIES (May, 2003)

202 The statements below are applicable to the following 203 Canadian Requirements:
incomplete vehicle types if the GVWR is 4536 kg The preceding statements for FMVSS 203 are
[10,000 lb] or less: appropriate compliance representations for CMVSS
• Chassis Cab 203, Driver Impact Protection, if this incomplete vehicle
• Incomplete E-Series Van or Wagon when was manufactured for sale or use in Canada. In such
equipped with front seats a case, the Basic (Stripped) Chassis will comply if no
• Cutaway when equipped with front seats components or attachments are added to the steering
control system that can catch the driver’s clothing or
This vehicle when completed, will conform to Standard jewelry during normal driving maneuvers.
202, Head Restraints, if:
• No alterations are made to the head restraints, the
seat assemblies and their anchorages, the floor pan, 204 INFORMATION
or floor pan reinforcements. Refer to the Design Recommendation section of the
• The added seat trim, on vehicles equipped with Ford Truck Body Builders’ Layout Book for Second
untrimmed front seats, is installed so that the physical Unit Body Attachment information that may aid in
dimension requirements for the head restraint, in this designing second unit bodies and their attachments to
Standard, are met. be compatible with E-Series vehicles.
Any front outboard passenger seat, added to a cutaway 204 The statements below are applicable to all incomplete
equipped with the School Bus Prep Package and when vehicle types except the Basic (Stripped) Chassis
completed as a truck, MPV, or bus (not school bus), if the GVWR is 4536 kg [10,000 lb] or less and the
must conform with the requirements of this Standard. Unloaded Vehicle Weight, when completed, is 2495
kg [5,500 lb] or less:
202 The statement below is applicable to the following
incomplete vehicle types if the GVWR is 4536 kg This vehicle, when completed, will conform to Standard
[10,000 lb] or less: 204, Steering Control Rearward Displacement, if:
• Incomplete E-Series Van with no front seats • No components are added which could influence the
• Cutaway with no front seats rearward displacement of the steering column.
• E-Series Basic (Stripped) Chassis • The steering column, steering intermediate and
coupling shaft, steering wheel, steering gear, steering
Conformity with Standard 202, Head Restraints, is not
linkage, related structural components, and attaching
substantially affected by the design of this incomplete
hardware, as installed by Ford Motor Company, are
vehicle; accordingly, Ford Motor Company makes no
not removed, relocated, altered, or modified in any
representation as to conformity with this Standard.
way.
203 The statement below is applicable to all incomplete • No alteration or modifications are made to the body
vehicle types except the Basic (Stripped) Chassis if chassis, drivetrain, or front suspension from the
the GVWR is 4536 kg [10,000 lb] or less: B-pillar forward.
This vehicle, when completed, will conform to Standard
204 The statement below is applicable to the following
203, Impact Protection for the Driver from the Steering
incomplete vehicle types if the GVWR is 4536 kg
Control System, if the steering control system is not
[10,000 lb] or less and the Unloaded Vehicle Weight,
removed, relocated, altered, or modified in any way and
when completed, is 2495 kg [5,500 lb] or less:
no components or attachments are added to the steering
control system that can catch the driver’s clothing or • E-Series Basic (Stripped) Chassis
jewelry during normal driving maneuvers. The Basic (Stripped) Chassis is designed by Ford Motor
203 The statement below is applicable to the following Company to be completed as a walk-in van type vehicle.
incomplete vehicle types if the GVWR is 4536 kg Walk-in vans are exempt from the requirements of
[10,000 lb] or less: Standard 204, Steering Control Rearward Displacement.
See walk-in van definition, on page 8.
• E-Series Basic (Stripped) Chassis
The Basic (Stripped) Chassis is designed by Ford Motor
Company to be completed as a walk-in van type vehicle.
Walk-in vans are exempt from the impact requirements
of Standard 203, Impact Protection for the Driver from
the Steering Control System. See walk-in van definition,
on page 8.

E-SERIES (May, 2003) 23 STATEMENTS OF CONFORMITY

205 The statement below is applicable to all incomplete 207, 208, 209, and 210 INFORMATION
vehicle types, except the Basic (Stripped) Chassis: For additional information to assist in designing seats,
This vehicle, when completed, will conform to seat belt systems, and seat belt anchorages that comply
Standard 205, Glazing Materials, if no alterations to with Standard 207, 208, 209, and 210 applicable to
or replacements of the installed glazing materials are Incomplete E-Series Van and Cutaway vehicles with
made and if additional glazing materials installed by no front seats provided by Ford Motor Company, refer
a subsequent stage manufacturer conforms to the to the Design Recommendation section of the Ford
requirements of Standard 205. Truck Body Builiders’ Layout Book for Seat and Lap &
205 The statement below is applicable to the following Shoulder Belt System information that is in addition to
incomplete vehicle types: the statements which follow.
• E-Series Basic (Stripped) Chassis 207 The statements below are applicable to the following
incomplete vehicle types when equipped with trimmed
Conformity with Standard 205, Glazing Materials, is not
front seats:
substantially affected by the design of this incomplete
vehicle: accordingly, Ford Motor Company makes no • Chassis Cab
representation as to conformity with this Standard. • Incomplete E-Series Van or Wagon
206 The statements below are applicable to all incomplete • Cutaway
vehicle types except the Basic (Stripped) Chassis, This vehicle, when completed, will conform to Standard
when completed as a Truck: 207, Seating Systems, if no alterations are made to the
This vehicle, when completed, will conform to Standard seat assemblies, their anchorages, the floor pan, or
206, Door Locks and Door Retention Components, if floor pan reinforcements. Any seating system added to
no alterations or adjustments are made to the door, this vehicle must conform to applicable requirements
door pillar structure, door locks, door latches, striker of this Standard. When the Cutaway is completed as a
plates, hinges, and attaching hardware as installed by school bus, see Standard 222 also.
Ford Motor Company. If the front seat attaching hardware is removed for any
Any door added to this vehicle by a subsequent stage reason, it must be reinstalled to the specifications in the
manufacturer must be equipped with door locks and Figures for E-Series on page 31.
door retention components that conform with this The Incomplete E-Series Recreational Van or the
Standard. Incomplete E-Series Wagon may have additional
206 The statement below is applicable to the following anchorages for rear seats other than the front driver
incomplete vehicle types, when completed as a and passenger seats. These locations apply to specific
Truck: hardware and designated seating positions used in
Ford completed vehicles. If these anchorages are
• E-Series Basic (Stripped) Chassis used without the appropriate Ford seats, seat belt
Conformity with Standard 206, Door Locks and Door systems, and hardware, Ford Motor Company makes no
Retention Components, is not substantially affected representation as to conformity with this Standard.
by the design of this incomplete vehicle; accordingly,
Ford Motor Company makes no representation as to 207 (Continued Next Page)
conformity with this Standard.

STATEMENTS OF CONFORMITY 24 E-SERIES (May, 2003)

207 (Continued) 207 The statements below are applicable to the following
incomplete vehicle types with no front seats:
207 The statements below are applicable to the following
incomplete vehicle types when equipped with • Incomplete E-Series Van
untrimmed front seats: • Cutaway
• Incomplete E-Series Van • E-Series Basic (Stripped) Chassis
• Cutaway Conformity with Standard 207, Seating Systems, is not
This vehicle when completed, will conform to Standard substantially affected by the design of this incomplete
vehicle; accordingly, Ford Motor Company makes no
207, Seating Systems, if: representation as to conformity with this Standard.
• No changes or modifications are made to the front The Cutaway, when equipped with seat delete option,
seat frames, latches, hardware, and padding. will include both front seat pedestals, pretensioner
• The weight of each completely trimmed front seat restraint systems, seat tracks, and a temporary driver’s
does not exceed the value in Table L on this page. seat. The pretensioner restraint system is attached to
• No modifications are made to the floor pan in the area the seat track. Therefore, the completed seat assembly
of the front seat attachments. must comply with the requirements of Standard 207
and 210.
• The front seat and seat belt anchorages are not
relocated. The Incomplete E-Series Recreational Van may have
additional seat anchorages. These locations apply to
If the front seat attaching hardware is removed for any
specific hardware and designated seating positions
reason, it must be reinstalled to the specifications in the
used in Ford completed vehicles. If these anchorages
Figures for E-Series on page 31.
are used without the appropriate Ford seats, seat belt
Any seating systems added to this vehicle must conform systems, and hardware, Ford Motor Company makes no
to the applicable requirements of this Standard. representation as to conformity with 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.

TABLE L
E-SERIES COMPLETED UNTRIMMED SEAT WEIGHT

MAX. WEIGHT (lb)

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 (May, 2003) 25 STATEMENTS OF CONFORMITY

208 NOTE • Any front overhead console installed on an Incomplete
An RCM (crash sensor and restraints control module) E-Series is configured as follows:
is located under the driver's seat. Care must be used – Front header (full width) overhead consoles may
to avoid damage to the RCM and sensor wiring during extend down no more than 2 inches as measured
removal or reinstallation of the driver's seat. Refer to from the Ford installed headliner† and extend
Figure E on page 33. rearward no more than 6 inches as measured from
208 The statements below are applicable to the Incomplete the midpoint between the Ford installed sun visor
E-Series Wagon and Van when equipped with trimmed inboard retaining clips (vehicle centerline).
front seats option if the GVWR is 3856 kg [8,500 – Center roof mounted consoles may extend down
lb] or less and the Unloaded Vehicle Weight, when no more than 3 inches as measured from the Ford
completed, is 2495 kg [5,500 lb] or less: installed headliner† and width is limited to 8 inches
This vehicle, when completed, will conform to Standard (4 inches either side of the vehicle centerline).
208, Occupant Crash Protection, if: – All overhead consoles are designed and
• The Unloaded Vehicle Weight exceeds 2166 kg [4775 manufactured to provide friendly surfaces on all
lb] for the E150 and 2268 kg [5000 lb] for the E250. sides and edges which could be contacted by an
occupant.
• The steering column, steering intermediate and
coupling shaft, steering wheel, steering gear, steering Any seat belt assemblies added to a vehicle must con-
linkage, related structural components, and attaching form to the applicable requirements of this Standard.
hardware, as installed by Ford Motor Company, are 208 The statements below are applicable to the incomplete
not removed, relocated, altered, or modified in any E-Series Van when equipped with untrimmed front
way. seats option if the GVWR is 3856 kg [8,500 lb] or less
• No components are added which could influence the and the Unloaded Vehicle Weight, when completed, is
rearward displacement of the steering column. 2495 kg [5,500 lb] or less:
• The seat belt components installed by Ford Motor This vehicle, when completed, will conform to Standard
Company are not removed, relocated, or altered. If the 208, Occupant Crash Protection, if:
seat belt components are temporarily removed for any • The Unloaded Vehicle Weight exceeds 2166 kg [4775
reason, they must be reinstalled to the specifications lb] for the E150 and 2268 kg [5000 lb] for the E250.
as shown in Figure A on page 30. • The steering column, steering intermediate and
• Front seats that have been removed for final coupling shaft, steering wheel, steering gear, steering
manufacture are reinstalled to the specifications as linkage, related structural components, and attaching
shown in the Figures on page 31. hardware, as installed by Ford Motor Company, are
• The seat belt warning system, as originally installed, not removed, relocated, altered, or modified in any
is not removed, replaced, modified, or altered in way.
any way. • No components are added which could influence the
• Window or roof modifications do not exceed the rearward displacement of the steering column.
defined cut out areas shown in the Figures on pages • The seat belt components installed by Ford Motor
34, 35, and 36. Company are not removed, relocated, or altered. If the
• No compressible material is installed between front seat belt components are temporarily removed for any
seat assembly and the floor pan. reason, they must be reinstalled to the specifications
for the appropriate vehicle type shown in Figure A
• No additional components or modifications are made on page 30.
to the areas defined at the Occupant Protection Zone
shown in Figure D on page 32. • Front seats that have been removed for final
manufacture are reinstalled to the specifications for
• The Air Bag Supplemental Restraint System as appropriate vehicle type as shown in the Figures
originally installed (see Figure E on page 33), is on page 31.
not removed, relocated, altered, or modified in any
way. • The seat belt warning system, as originally installed,
is not removed, relocated, altered, or modified in
• The Air Bag Supplemental Restraint System any way.
Information Labels that are affixed to the front sun
visors are visible, and not altered, modified, or • The completed front seats are within the Seating
removed. If the Air Bag Supplemental Restraint Reference Point specifications in Figure C on page
System Information Labels are not affixed to the 32.
front visors but shipped in dunnage, the following is • Window or roof modifications do not exceed the
necessary to meet Standard 208: defined cut out areas shown in the Figures on pages
– The information label must be permanently affixed 34, 35, and 36.
to each visor in an upright position readable from • No compressible material is installed between front
the driver’s or passenger’s seating position. seat assembly and the floor pan.
– If the label is not visible when the visor is stored • No additional components or modifications are made
(up position), an Air Bag Alert Label shall be placed to the areas defined as the Occupant Protection Zone
on the visible surface of the visor as specified in shown in Figure D on page 32.
Section 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 208 (Continued Next Page)
forward.
†The Headliner Plane is defined on Figure G3 page 36, for vehicles
without the Ford headliner.

STATEMENTS OF CONFORMITY 26 E-SERIES (May, 2003)

208 (Continued) 208 The statements below are applicable to the Incomplete
• The Air Bag Supplemental Restraint System as E-Series Van with seat delete option, if the GVWR is
originally installed (see Figure E on page 33), is 3856 kg [8,500 lb] or less and the Unloaded Vehicle
not removed, relocated, altered, or modified in any Weight, when completed, is 2495 kg [5,500 lb] or
way. less:
• The Air Bag Supplemental Restraint System A seat delete option includes (does not delete) front seat
Information Labels that are affixed to the front sun pedestals, front seat tracks, front seat belt and buckle
visors are visible, and not altered, modified, or assemblies mounted to the seat tracks, restraint system,
removed. If the Air Bag Supplemental Restraint and fasteners, and comes with a temporary transit
System Information Labels are not affixed to the seat. Because the permanent seats to be installed
front visors but shipped in dunnage, the following is by a subsequent stage manufacturer are critical to
necessary to meet Standard 208: the performance of the completed vehicle and to the
– The information label must be permanently affixed dynamic test requirements of Standard 208, Occupant
to each visor in an upright position readable from Crash Protection, conformity to this Standard is not
the driver’s or passenger’s seating position. substantially affected by the design of this incomplete
vehicle.
– If the label is not visible when the visor is stored
(up position), an Air Bag Alert Label shall be placed Ford offers the following information and guidelines to
on the visible surface of the visor as specified in assist subsequent stage manufacturers who choose
Section 4.5.1(c) of Standard 208. to install front seat assemblies in Incomplete E-Series
Van vehicles.
• After the front seats and B-pillar trim are installed, the
seat belt system components must comply with: • The completed front seat assemblies include the
following Ford Motor Company components: Seat
– Adjustment requirements specified by s7.1 as pedestal, seat tracks, restraint system, and all
these requirements apply to seat belt fit, to the fasteners provided, and the fasteners are torqued to
intersection of the upper torso belt with the lap belt, the specifications listed in Figure B on page 31.
and to child seat lockability, and
• The completed front seat assemblies, when installed,
– Latch mechanism requirements specified by s7.2 will have the same location, construction, and spatial
as these requirements apply to the accessibility of relationship to the seating system as provided by
seat belt components, and Ford Motor Company.
– Latch plate access, retraction, seat belt guides, and • The Unloaded Vehicle Weight exceeds 2166 kg [4775
hardware requirements specified by s7.4 as these lb] for the E150 and 2268 kg [5000 lb] for the E250.
requirements apply to comfort and convenience
requirements of the seat belt system. • The steering column, steering intermediate and
coupling shaft, steering wheel, steering gear, steering
• The seat hardware including the seat back frames linkage, related structural components, and attaching
are free of sharp edges to prevent damage to the hardware, as installed by Ford Motor Company, are
seat belt webbing during an impact. not removed, relocated, altered, or modified in any
• Do not obstruct the E-Series seat belt path in the way.
area of “Point A” (Figure C, page 32). All seat belt • No components are added which could influence the
contactable surfaces must be free of burrs, parting rearward displacement of the steering column.
lines, sharp edges, or any other impediment that
could impair or damage the seat belt in load bearing • The seat belt components installed by Ford Motor
situations. Company are not removed, relocated, or altered. If the
seat belt components are temporarily removed for any
• No alteration or modifications are made to the reason, they must be reinstalled to the specifications
body chassis (including front bumper), drivetrain, as shown in Figure A on page 30.
body mounts, or front suspension from the B-pillar
forward. • The completed front seats are installed to the
specifications as shown in the Figures on page 31.
• Any front overhead console installed on an Incomplete
E-Series is configured as follows: • The seats, seating hardware, seat belt warning
system, and all attaching hardware are installed in
– Front header (full width) overhead consoles may accordance with, and comply with, this Standard and
extend down no more than 2 inches as measured Standard 207, Seating Systems.
from the Ford installed headliner† and extend
rearward no more than 6 inches as measured from • The completed front seats, when installed, are located
the midpoint between the Ford installed sun visor within the dimensional specifications for the Seating
inboard retaining clips (vehicle centerline). Reference Point and the torso angle is positioned as
specified in Figure C on page 32.
– Center roof mounted consoles may extend down
no more than 3 inches as measured from the Ford • Window or roof modifications do not exceed the
installed headliner† and width is limited to 8 inches defined cut out areas shown in the Figures on pages
(4 inches either side of the vehicle centerline). 34, 35, and 36.
– All overhead consoles are designed and
manufactured to provide friendly surfaces on all
sides and edges which could be contacted by an 208 (Continued Next Page)
occupant.
Any seat belt assemblies added to this vehicle
must conform to the applicable requirements of this
†The Headliner Plane is defined on Figure G3 page 36, for E-Series
Standard. vehicles without the Ford headliner.

E-SERIES (May, 2003) 27 STATEMENTS OF CONFORMITY

208 (Continued) • Any front overhead console installed on an Incomplete
• No compressible material is installed between front E-Series is configured as follows:
seat assembly and the floor pan. – Front header (full width) overhead consoles may
• No additional components or modifications are made extend down no more than 2 inches as measured
to the areas defined as the Occupant Protection Zone from the Ford installed headliner† and extend
shown in Figure D on page 32. rearward no more than 6 inches as measured from
the midpoint between the Ford installed sun visor
• The Air Bag Supplemental Restraint System as inboard retaining clips (vehicle centerline).
installed by Ford Motor Company is not removed,
relocated, modified, or altered in any way as shown – Center roof mounted consoles may extend down
in Figure E on page 33. no more than 3 inches as measured from the Ford
installed headliner† and width is limited to 8 inches
• The Air Bag Supplemental Restraint System (4 inches either side of the vehicle centerline).
Information Labels that are affixed to the front sun visors
are visible and not altered, modified, or removed. If the • All overhead consoles are designed and manufactured
Air Bag Supplemental Restraint System Information to provide friendly surfaces on all sides and edges
Labels are not affixed to the front visors but shipped in which could be contacted by an occupant.
dunnage, the following is necessary to meet Standard Any seat belt assemblies added to this vehicle
208: must conform to the applicable requirements of this
– The information label must be permanently affixed Standard.
to each visor in an upright position readable from 208 The statements below are applicable to the following
the driver’s or passenger’s seating position. incomplete vehicle types when equipped with
– If the label is not visible when the visor is stored untrimmed front seats or seat delete option and
(up position), an Air Bag Alert Label shall be placed either the GVWR is over 3856 kg [8500 lb], or the
on the visible surface of the visor as specified in Unloaded Vehicle Weight, when completed, is over
Section 4.5.1(c) of Standard 208. 2495 kg [5500 lb]:
• After the front seats and B-pillar trim are installed, the • Incomplete E-Series Van
seat belt system components must comply with: • Chassis Cab
– The seat belt buckle pretensioner, air bags, and • Cutaway
electronic sensor module are bar coded with a A seat delete option includes (does not delete) front
unique serial number which is matched to the seat pedestals, front seat tracks, front seat belt and
vehicle VIN. The completed vehicle must contain buckle assemblies mounted to the seat tracks, restraint
the same seat belt buckle pretensioner, air bags, system, and fasteners, and comes with a temporary
and electronic sensor module that were installed by transit seat.
Ford Motor Company in the incomplete vehicle. This vehicle, when completed, will conform to Standard
– Adjustment requirements specified by s7.1 as 208, Occupant Crash Protection, if:
these requirements apply to seat belt fit, to the • The seat belt components installed by Ford Motor
intersection of the upper torso belt with the lap belt, Company are not removed, relocated, altered, or
and to child seat lockability, and modified. If the seat belt components are temporarily
– Latch mechanism requirements specified by s7.2 removed for any reason, they are reinstalled to the
as these requirements apply to the accessibility of specifications for E-Series shown in Figure A on page
seat belt components, and 30 and Figure B on page 31.
– Latch plate access, retraction, seat belt guides, and • After the front seats and B-pillar trim are installed, the
hardware requirements specified by s7.4 as these seat belt system components comply with:
requirements apply to comfort and convenience – Adjustment requirements specified by s7.1 as
requirements of the seat belt system. these requirements apply to seat belt fit, to the
• The seat hardware including the seat back frames intersection of the upper torso belt with the lap belt,
are free of sharp edges to prevent damage to the and to child seat lockability, and
seat belt webbing during an impact. – Latch mechanism requirements specified by s7.2
• Do not obstruct the E-Series seat belt path in the as these requirements apply to the accessibility of
area of “Point A” (Figure C, page 32). All seat belt seat belt components, and
contactable surfaces must be free of burrs, parting – Latch plate access, retraction, seat belt guides, and
lines, sharp edges, or any other impediment that hardware requirements specified by s7.4 as these
could impair or damage the seat belt in load bearing requirements apply to comfort and convenience
situations. requirements of the seat belt system.
• No alteration or modifications are made to the • No actions are taken which would impair the integrity
body, chassis (including front bumper), drivetrain, of the seat belt systems and the seat belt warning
body mounts, or front suspension from the B-pillar system.
forward.

208 (Continued Next Page)

†The Headliner Plane is defined on Figure G3 page 36, for E-Series

vehicles without the Ford headliner.

STATEMENTS OF CONFORMITY 28 E-SERIES (May, 2003)

 • The Air Bag Supplemental Restraint System as 208 The statement below is applicable to the following
installed by Ford Motor Company (see Figure E on vehicle types:
page 33) is not removed, relocated, modified or • E-Series Basic (Stripped) Chassis
altered in any way. Ford technical bulletin procedures
Conformity with Standard 208, Occupant Crash
for relocating the floor-mounted restraints delete
Protection, is not substantially affected by the design
resistor and bracket may be followed for vehicles
of this incomplete vehicle; accordingly, Ford Motor
that have an option that deletes the front passenger
Company makes no representation as to conformity
restraint system.
of this vehicle. Any seat belt assemblies added to this
• The Air Bag Supplemental Restraint System vehicle must conform to the applicable requirements
Information Labels that are affixed to the front of this Standard.
sunvisors are visible and not altered, modified, or
removed. 208 Canadian Requirements:
Any seat belt assemblies added to this vehicle The preceding statements and supporting figures
must conform to the applicable requirements of this for FMVSS 208, on pages 26-36, are appropriate
Standard. compliance representations for CMVSS 208, Occupant
Restraint Systems in Frontal Impact, if this incomplete
208 The statement below is applicable to the following vehicle was manufactured for sale or use in Canada.
incomplete vehicles when equipped with Ford In such a case, CMVSS 208 paragraphs (13), (14),
trimmed front seats and either the GVWR is over 3856 and (15) are substituted for the reference to FMVSS
kg [8500 lb], or the Unloaded Vehicle Weight, when 208 Section 7.1; CMVSS 208 paragraph (20) should
completed, is over 2495 kg [5500 lb]: be substituted for the reference to FMVSS 208 Section
• Chassis Cab 7.2; and CMVSS 208 paragraphs (29), (30), (31),
• Incomplete E-Series Van or Wagon (32), (33), (34), (35), (36), (37), (38), (39), and (40)
• Cutaway should be substituted for the reference to FMVSS 208
Section 7.4.
This vehicle, when completed, will conform to Standard
208, Occupant Crash Protection, if:
• The seat belts, seat belt warning system, and
attaching hardware installed by Ford Motor Company
are not removed, relocated, altered, or modified.
• No actions are taken which would impair the integrity
of the belt and seat belt warning systems. (A seat belt
warning system is not required for a vehicle with a
GVWR over 4536 kg [10,000 lb] or for a bus).
• Any rear seats installed by Ford Motor Company
that are temporarily removed for any reason are
returned to their original location and condition in
the vehicle.
• The Air Bag Supplemental Restraint System as
installed by Ford Motor Company (see Figure E on
page 33) is not removed, relocated, modified or
altered in any way. Ford technical bulletin procedures
for relocating the floor-mounted restraints delete
resistor and bracket may be followed for vehicles
that have an option that deletes the front passenger
restraint system.
• The Air Bag Supplemental Restraint System
Information Labels that are affixed to the front
sunvisors are visible and not altered, modified, or
removed. If the Air Bag Supplemental Restraint
System Information Labels are not affixed to the
front visors but shipped in dunnage, the following is WARNING:
necessary to meet Standard 208: VEHICLES EXCEPT STRIPPED CHASSIS, INCLUDING
– The information label must be permanently affixed THOSE OVER 3856 kg [8500 lb] GVWR AND/OR OVER
to each visor in an upright position readable from 2495 kg [5500 lb] UVW ARE EQUIPPED WITH A FRONT
the driver’s or passenger’s seating position. ROW OCCUPANT SUPPLEMENTAL RESTRAINT
– If the label is not visible when the visor is stored SYSTEM (AIRBAG(S), WIRING, AND SENSORS
(up position), an Air Bag Alert Label shall be placed INCLUDING AN RCM UNDER DRIVER'S SEAT)
on the visible surface of the visor as specified in AND PYROTECHNIC BUCKLE PRETENSIONER(S).
Section 4.5.1(c) of Standard 208. DELETE OF FRONT PASSENGER ACCOMMODATIONS
INCLUDING RESTRAINTS, SEAT, AND PEDESTAL
Any seat belt assemblies added to this vehicle COUPLED WITH THE ADDITION OF DELETE
must conform to the applicable requirements of this RESISTORS IN THE SENSOR SYSTEM CIRCUITRY IS
Standard. AVAILABLE ON SOME VEHICLES. MODIFICATIONS
TO THE VEHICLE FORWARD OF OR NEAR THE
CRASH SENSORS SHOWN IN FIGURE E PAGE 33 MAY
EFFECT THE DEPLOYMENT OF THE AIRBAG(S) AND
PRETENSIONER(S).

E-SERIES (May, 2003) 29 STATEMENTS OF CONFORMITY

 3C24-15602B82
FRONT OF PIA
F65B-15602B90 ADJ. ASY.
VEHICLE BOLTTORQUE F65B-602B90
3C24-15602B82 COVER ASY. 40.0 ± 6.0 Nm
COVER ASY.
[29.5 ± 4 ftlb]
ADJ. ASY.
PANEL ASY.
UPPER CUTAWAY & VAN MODELS

3C24-1560262 3C24-1560262
COVER ASY. COVER ASY.
FRONT OF
1 REQ’D. EA. SIDE 1 REQ’D. EA. SIDE
VEHICLE

N806773-S190
NUT - TORQUE
40.0 ± 6.0 Nm
PIA [29.5 ± 4 ftlb]
BOLT-TORQUE
40.0 ± 6.0 Nm 15611B09 N806773-S190
[29.5 ± 4 ftlb] BELT AND NUT - TORQUE
RETRACTOR ASY. 40.0 ± 6.0 Nm
[29.5 ± 4 ftlb]
PIA
BOLT-TORQUE 15611B08
47.5 ± 7.2 Nm BELT AND
[35 ± 5 ftlb] RETRACTOR ASY.
ALL CUTAWAY
SHIPPING CLIP MUST
MODELS ONLY
PIA REMAIN CLIPPED TO
BOLT - TORQUE BELT PRIOR TO
368273-S100 47.5 ± 7.2 Nm ATTACHMENT TO
BOLT - TORQUE [35 ± 5 ftlb] RETRACTOR INTO
47.5 ± 7.2 Nm VEHICLE.
B [35 ± 5 ftlb]

VIEW A
SHIPPING CLIP MUST A
REMAIN CLIPPED TO A VIEW A
BELT PRIOR TO
ATTACHMENT TO PANEL ASY.
ALL CUTAWAY
RETRACTOR INTO COVER
VIEW B MODELS ONLY
VEHICLE.
PANEL ASY. COVER
ALL WAGON - VAN MODELS ONLY ALL WAGON - VAN MODELS ONLY
DRIVER - SEAT CRITICAL CONTROL ITEM PASSENGER SEAT CRITICAL CONTROL ITEM
(LEFT HAND) INSTALLATION (RIGHT HAND) INSTALLATION

IVM0040

INTERIOR TRIM
9.5 RADIUS MIN.
[.37 IN] RETRACTOR
12.5 MIN.
UP [.50 IN]
ADJUSTED OVERLAP 6.0
[.24 IN]
POSITION
6.5 MIN. FROM
[.25 IN]
RELEASE KNOB
3.0
TO INTERIOR TRIM
[.12 IN]
SECTION DD UP POSITION
13.0 MIN. FROM
DOWN [.50 IN]
ADJUSTED COVER TO VIEW IN CIRCLE C
POSITION RELEASE KNOB
2.0 MIN. 6.0 MIN.
[.08 IN] C [.24 IN]
(3) FULL (WITH DRING A
THREAD LOCATED ON 6.0 MIN. CLEARANCE
EXPOSED SHLDR.BOLT) [.24 IN]
AROUND BELT
A PERIPHERY AT MAX.
1560262 REF. TRAVEL POSITIONS

SEAT BELT
B WEBBING
B
D 6.0 MIN.
[.24 IN]
FRONT OF
VEHICLE
6.0 MIN. CLEARANCE D SECTION BB
[.24 IN]
TO ALL ADJUSTED MAIN VIEW
POSITIONS
SECTION AA NOTE: ALL DIMENSIONS ARE IN MILLIMETERS [ ] DIMENSIONS ft-lb OR INCHES

IVM0041

FIGURE A – E-SERIES FRONT SEAT RESTRAINT SYSTEM

STATEMENTS OF CONFORMITY 30 E-SERIES (May, 2003)

 SEAT ASY.
SEAT ASY.

PIA BOLT
TORQUE
+ 6.0 Nm
35.0 -
[29.5 + 4 ft-lb]
-

N801078-S58
SCREW M8x1.25
HEX 4 REQ’D.
TORQUE
N801078-S424 25.0 +
- 3.8 Nm
SCREW M8 x 1.25 HEX [18.4 +
- 2.8 ft-lb]
4 REQ’D. 4C24-15618B47-AA
TORQUE 25.0 - + 3.8 Nm TRACK ASY.
[18.4 -
+ 2.8 ft-lb]
2C24-1561701-A XC2A-1561202-A
F8UB-14A699-A PYROTECHNIC
POWER TRACK A IC24-15618B46-B
WIRING ASYSEAT ASY. R.H.
FRT. ST. TRACK ASY.
CONTROL FEED
JUMPER 56912-S58 2C241561755A PIA BOLT
SCREW 4.2 x 19 HANDLE FRT. ST. TORQUE
TAPPING TRACK + 5.0 Nm
35.0 -
+ 4 ft-lb]
[29.5 -
F7US-14A699DB
WIRE ASY. COVERFRT.
ST. PIVOT

F8UB-14A699AA
WIRING ASYSEAT 56912-S58
2C24-1562506-A SCREW 4.2 x 19.0
CONTROL FEED N800937-S424
SUPPORT ASY. TAPPING
JUMPER NUT & WASHER ASY.
(R.H. MNL) 1C2415466B00A
2 REQ’D. BRKT CHILD SEAT
55.0 + 611D02A
- 8.3 Nm
[40.6 -
+ 6 ft-lb] STUD COVER
XL3T-14A701-A N620432-S58
4 REQ'D.
SWITCH ASY. M10 HEX NUT HD.
ST. CONTROL N802351-S424 N811326S424 NUT W/WASHER N802351S424
STUD 2 REQ’D. SCREW 2 REQ’D. 4 REQ’D. STUD 2 REQ’D.
XC25-1560094-B W705944-S424 55.0 +
- 8.3 Nm
N620481-S58 [40.6 +
SUPPORT ASY. SCREW 2 REQ’D. NUT M8 x 1.75 HEX FLANGE - 6 ft-lb] MANUAL R.H. SHOWN
611D02A 55.0 +
- 8.3 Nm TORQUE 25.0 +
[40.6 + 6 ft-lb] - 3.8 Nm
STUD COVER - [18.4 +
- 2.8 ft-lb]
4 REQ’D.
POWER L.H. SHOWN
IVM0023

E-SERIES DRIVER (L.H.) SEAT INSTALLATION E-SERIES PASSENGER (R.H.) SEAT INSTALLATION

PIA BOLT
TORQUE
+ 6.0 Nm
40.0 -
+ 4 ft-lb]
[29.5 - 579988 CLEARANCE
SEAT ZONE
O
10 CLEARANCE
DR. 3C34-1561203-A O ZONE
PASS XC2A-156202-A 15 O 10
BUCKLE ASY.
45 O
PRE
SS
FOR SHIPPING
PURPOSES ONLY,
ONLY 4 SCREWS (NO
NUTS & BOLTS)
COVER FRT
ST. PVT.

A
DR. 571485 611D02A
PASS. 571481 STUD COVER
R.H. TRACK 4 REQ’D.

N800937-S424
NUT & WASHER ASY.
SIDE VIEW REAR VIEW
2 REQ’D.
55.0 + VIEW A
- 8.3 Nm
[40.6 +
- 6 ft-lb]
FRONT OF VEHICLE CENTER OF VEHICLE

O/B TRUCKS PRETENSIONER CLEARANCE ZONE

W705944-S424 571483 DR.
SCREW 2 REQ’D. 571479 PASS. IMPORTANT:
55.0 +
- 8.3 Nm R.H. TRACK THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS.
+ 6 ft-lb]
[40.6 - THE BUCKLE MOVES DOWNWARD THROUGH THE SHADED
F7U-S14A699DB ZONE AND MUST NOT CONTACT ANY COMPONENT WHICH
N011488-S424
WIRE ASY. MAY DEGRADE ITS PERFORMANCE.
STUD 2 REQ’D.
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED
2C24-1561755-B (DR.) XC25-1560094-A (MANUAL) AREA, OR ALTER OR MODIFY THIS AREA.
HDL.FRT.ST.TRK. SUPPORT ASY.
[ ] DIMENSIONS ft-lb OR INCHES

E-SERIES DRIVER (L.H.) SEAT DELETE OPTION

FIGURE B – E-SERIES FRONT SEAT INSTALLATION

E-SERIES (May, 2003) 31 STATEMENTS OF CONFORMITY

 SRP INFORMATION POINT A
(SEAT POSITION IS 10.0mm [0.39] FORWARD (SEAT POSITION IS AT THE MIDPOINT
OF REARMOST POSITION) OF AVAILABLE TRAVEL)

A B C D E F
MIN. MAX.
DRIVER - SEAT (VAN AND CUTAWAY) 217.8 105.0 384.2 356.0 67.0 937.4
[8.57] [4.13] [15.13] [14.01] [2.64] [36.90]
PASSENGER - SEAT (VAN AND CUTAWAY) 277.3 103.0 377.0 412.0 65.0 960.1
[10.92] [4.06] [14.84] [16.22] [2.56] [37.80]

THE TORSO ANGLE IS DETERMINED BY

USING THE METHOD SPECIFIED IN
SAE J826 (MAY 1987)
18 DRIVER
E E 21 PASSENGER
C TORSO ANGLE
POINT A POINT A L OUTSIDE D
FRONT
POINT A
FASTENER
A

C F
SEAT SEAT
BASE BASE

B B

CL OUTSIDE CL OUTSIDE 6.0

[0.24] 510.0 SEAT BACK
FRONT FRONT [20.08]
HEEL PIVOT
FASTENER FASTENER
POINT
PASSENGER SEAT DRIVER SEAT
C
L
VEHICLE SRP HAS A 12.7 [0.50] RADIAL
DRIVER SIDE ONLY TOLERANCE PERMITTED FROM
IMPORTANT: BASE SRP
THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE AT
DESIGN POSITION. ECONOLINE VAN VEHICLES AT DESIGN POSITION
WILL BE LEVEL FRONT TO REAR, AND SIDE TO SIDE, ON THE UPPER
[ ] DIMENSIONS ARE INCHES
SURFACE OF THE RIBBED FLOOR PANEL FROM THE BPILLAR REARWARD.

FIGURE C - E-SERIES SEATING REFERENCE POINT (SRP)

DO NOT INSTALL ADDITIONAL COMPONENTS IN THE

SHADED AREAS, OR ALTER OR MODIFY THESE AREAS.

FIGURE D - E-SERIES OCCUPANT PROTECTION ZONE

STATEMENTS OF CONFORMITY 32 E-SERIES (May, 2003)

 RESTRAINT CONTROL MODULE
UNDER DRIVER'S SEAT

STEERING
INSTRUMENT WHEEL
PANEL
HARNESS
DRIVER
PASSENGER AIRBAG
AIRBAG

READINESS
INDICATOR

RESTRAINTS
CONTROL MODULE
(ON FLOOR UNDER
DRIVER SEAT)

CONNECTOR
AT SAFETY
WALL
FRONT
CRASH ENGINE
SENSOR COMPARTMENT
HARNESS

DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS

OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS
THAT ARE IDENTIFIED IN THIS ILLUSTRATION. DO NOT RELOCATE. MUST BE METAL-TO-METAL
CONTACT

FIGURE E1 - 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.

14B321-A SNS & BRKT N808248-S190 SCREW

ASY - A/BAG FRT (12.0 ± 1.8 N.m TORQUE)
14A200 WIR ASY -
WDO REG RLY SW

REF FRONT
FLOOR PAN

FRONT OF
VEHICLE

FIGURE E3 - E-SERIES RESTRAINT CONTROL MODULE

E-SERIES (May, 2003) 33 STATEMENTS OF CONFORMITY

 CUT LINE CUT LINE

CUT LINE
SECTION CC
SECTION BB

CUT LINE

CUT LINE

SECTION AA SECTION DD

711.2 711.2
[ 28.00 ] [ 28.00 ]
MAXIMUM MAXIMUM

THE SPOTWELDS (X) IN THIS

AREA MUST REMAIN INTACT.
B

A A C C D D

FRONT OF
VEHICLE

NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS.

THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW
FOR THE PURPOSE OF CLARITY.
[ ] DIMENSIONS ARE INCHES

FIGURE G1 - BODY PANEL WINDOW REMOVAL AREA – E-SERIES (DRIVER SIDE – L.H.)

STATEMENTS OF CONFORMITY 34 E-SERIES (May, 2003)

 CUTLINE

SECTION FF
CUTLINE CUTLINE

SECTION EE SECTION GG

THE SPOTWELDS ( X ) IN
THIS AREA MUST REMAIN
INTACT.

F
533.4
[21.00]
MAXIMUM WITH
SLIDING DOOR

E E 711.2
G G
[28.00]
MAXIMUM
WITH CARGO
DOORS

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 G2 - BODY PANEL WINDOW REMOVAL AREA – E-SERIES (PASSENGER SIDE - R.H.)

E-SERIES (May, 2003) 35 STATEMENTS OF CONFORMITY

 END OF ROOF
EXTENDED VAN

END OF ROOF
OUTER EDGE REGULAR VAN
END OF ROOF OF TROUGH
CUTAWAY

CL

"B" PILLAR
REINFORCEMENT

50.8 203.2 203.2

WINDSHIELD [2.00] [8.00] [8.00]
HEADER

SECTION AT
CL OF ROOF CUT
LINE CUT
FORWARD
LINE
CUT 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 G3 - ROOF PANEL REMOVAL AREA - E-SERIES

STATEMENTS OF CONFORMITY 36 E-SERIES (May, 2003)

209 The statements below are applicable to the following 210 The statements below are applicable to all incomplete
incomplete vehicle types with front seat(s): vehicle types except Basic (Stripped) Chassis:
• Chassis Cab This vehicle, when completed, will conform to Standard
• Incomplete E-Series Van or Wagon 210, Seat Belt Assembly Anchorages, if:
• Cutaway • No alterations are made to the front seat belt
This vehicle, when completed, will conform to Standard anchorages, front seat belt assemblies, floor pan,
209, Seat Belt Assemblies, if: floor pan reinforcements, or body mounts.
• No alterations or replacements are made to the seat • No alterations are made to the rear cab panel or roof
belt assemblies and attaching hardware. for the Chassis Cab.
• No action is taken that would impair the integrity of • E-Series window or roof modifications do not exceed
the seat belt system provided. the defined cut out areas shown in the Figures on
pages 34, 35, and 36.
Any seat belt assemblies added to a vehicle must
conform to the requirements of this Standard. The Incomplete E-Series Van and Cutaway with no front
seats must have completed front seats installed that
209 The statement below is applicable to the following conforms to the seat location criteria shown in Figure
incomplete vehicle types with no front seats: C on page 32.
• Incomplete E-Series Van The Incomplete E-Series Van, Wagon, and Cutaway
• Cutaway must have a seat belt anchorage system installed
Conformity with the pelvic restraint, upper torso restraint, for each additional designated seating position that
release, adjustment, and webbing requirements of conforms to the applicable requirements of this
Standard 209, Seat Belt Assemblies as specified in Standard.
s4.1 (b), (c), (e), (g), and (h), respectively, is not The Incomplete E-Series Recreational Van or the
substantially affected by the design of this incomplete E-Series Wagon may have additional seat belt
vehicle; accordingly Ford Motor Company makes no anchorages for designated seating positions other than
representation as to conformity with these requirements the front driver and passenger seats. Also, Chassis
of Standard 209. However, Ford Motor Company Cab vehicles may have additional seat belt anchorages
represents that the seat belt assemblies provided for designated seating positions on optional seats not
by Ford Motor Company conform to the applicable provided on incomplete vehicles. These locations apply
single occupancy hardware, attachment hardware, to specific hardware and designated seating positions
strap, marking, installation instructions, usage and used in Ford completed vehicles. If these anchorages
maintenance instructions, workmanship, webbing are used without the appropriate Ford seats, seat belt
performance, hardware performance, and assembly systems, and hardware, Ford Motor Company makes no
performance requirements detailed in the remaining representation as to conformity with this Standard.
paragraphs of the standard not specified above,
The Incomplete E-Series Recreational Van, when
provided no alterations or replacements are made
equipped with the seat delete option, will include both
to the seat belt assemblies and attaching hardware,
front seat pedestals, pretensioner restraint systems, seat
as provided by Ford Motor Company, and further
tracks, and a temporary driver’s seat. The pretensioner
provided that no action is taken by subsequent stage
restraint system is attached to the seat track, therefore,
manufacturers to impair the integrity of the seat belt
the completed seat assembly must comply with the
system provided. Any additional seat belt assemblies
requirements of Standard 210 and 207.
installed must conform to the requirements of this
Standard. 210 The statement below is applicable to the following
incomplete vehicle types (Type III):
209 The statement below is applicable to the following
incomplete vehicle types: • E-Series Basic (Stripped) Chassis
• E-Series Basic (Stripped) Chassis Conformity with Standard 210, Seat Belt Assembly
Anchorages, is not substantially affected by the design
Conformity with Standard 209, Seat Belt Assemblies, is
of this incomplete vehicle; accordingly, Ford Motor
not substantially affected by the design of this incomplete
Company makes no representation as to conformity
vehicle; accordingly Ford Motor Company makes no
with this Standard.
representation as to conformity with this Standard.
210.1 Canadian Requirements applicable to all incomplete
209 Canadian Requirements:
vehicle types with a GVWR of 3856 kg [8,500 lb] or
The preceding statements for FMVSS 209 are less and an unloaded vehicle weight of 2495 kg [5500
appropriate compliance representations for CMVSS lb] or less except Basic Stripped Chassis:
209, Seat Belt Assemblies, if this incomplete vehicle
was manufactured for sale or use in Canada. In such 210.1 (Continued on Next Page)
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.

E-SERIES (May, 2003) 37 STATEMENTS OF CONFORMITY

210.1 (Continued) 212/ Note
This vehicle, when completed, will conform to Standard 219 The terms “body” or “body structure,” in the 212 and
210.1, User-Ready Tether Anchorages for Restraint 219 statements that follow, include any equipment
Systems, if: permanently attached to that body or body structure
installed by the subsequent stage manufacturer as well
• No alternations are made to the front passenger seat as the basic body or body structure.
tether anchorages and access to the anchorages
is not restricted. 212/ INFORMATION
219 Refer to the Design Recommendations section in the
For the incomplete E-Series Van and Cutaway with
Ford Truck Body Builders’ Layout Book for Second Unit
no front seats:
Body Attachment information to aid in designing second
• If a front passenger seat is installed, it must have the unit bodies and their attachments for compatibility with
required tether anchor. E-Series vehicles.
• If the E-Series is completed as a Multipurpose 212/ The statements below are applicable to the following
Passenger Vehicle (MPV) and a second forward 219 Incomplete vehicle types if the GVWR is 4536 kg
facing row of designated seating is installed, for a [10,000 lb] or less:
total of five or fewer seating positions, at least two
• Incomplete E-Series Van or Wagon
of the second row forward facing seats must have
the required tether. • Cutaway
• If the E-Series is completed for certification as a This vehicle, when completed, will conform to Standard
Truck and a second row of designated seating is 212 Windshield Mounting, and Standard 219, Windshield
installed, then all of the second row seats must have Zone Intrusion, if:
tether anchors. • The following windshield system components, related
• If there are more than five designated seating structural components, and hardware, as installed
positions, at least three of the forward facing seating by Ford Motor Company, are not removed, relocated,
positions to the rear of the first row must have the altered, or modified in any way except as specified
required tether. in this manual:
210.1 Canadian Requirements applicable to the following – Windshield and windshield mounting system
incomplete vehicle types: – Cab and front end structural components including
• E-Series Basic (Stripped) Chassis the roof, pillars, cowl, cowl reinforcements,
hood, doors, fenders, hood restrictors and
Conformity with Standard 210.1, User-Ready apron reinforcements, and frame and frame
Tether Anchorages for Restraint Systems, is not reinforcements
substantially affected by the design of these incomplete
vehicles; accordingly, Ford Motor Company makes no – Radio antenna and air cleaner assembly
representations as to conformity with this Standard. – Doors and hood mounting, hinging, and latching
210.2 Canadian Requirements: systems
– Hood ornamentation
The statement below is applicable to all incomplete
vehicle types if the GVWR is 3856 kg [8,500 lb] or less, – Bumper and bumper mounting system†
except Basic Stripped Chassis. It is also applicable to • No alteration or modification made to the incomplete
buses (including school buses) with a GVWR of 4536 vehicle as manufactured by Ford Motor Company
kg [10,000 lb] or less: and no components or structure installed by a
This vehicle, when completed, will conform to Standard subsequent stage manufacturer results in any loss of
210.2, Lower Universal Anchorage Systems for Restraint windshield retention (as defined in Standard 212) or
Systems and Booster Cushions, if: any penetration of the inner surface of the windshield
or intrusion into the protected zone (as defined in
• No alterations are made to the front passenger seat
Standard 219) when the vehicle is impacted in any
tether anchorages or LATCH lower anchors, and
manner specified by applicable provisions of Standard
access to the anchorages is not restricted, and
212 or Standard 219. Sections S6.1(b) and S7.7(b) of
no alterations are made to the seat assemblies,
Standards 212 and 219, respectively, state vehicles
their anchorages, the floor pan or floor pan
are tested to a maximum Unloaded Vehicle Weight
reinforcements.
of 2495 kg [5500 lb].
Because the addition of seats may change the
• The completed vehicle’s Unloaded Vehicle Weight
number and/or location for lower anchors required
does not exceed the value designated in Table A
by this Standard, Ford Motor Company makes no
on page 15 corresponding to the vehicle's model
representations as to conformity with this Standard for
and wheelbase.
any vehicle that has seats added by Intermediate or
Final Stage Manufacturers.
210.2 Canadian Requirements:
The statement below is applicable to the following
incomplete vehicle types:
• E-Series Basic (Stripped) Chassis
Conformity with Standard 210.2, Lower Universal
Anchorage Systems for Restraint Systems and Booster
Cushions, is not substantially affected by the design
of this incomplete vehicle; accordingly, Ford Motor † Temporary removal of the front bumper and front bumper mounting
system during manufacture and reinstallation in accordance with
Company makes no representations as to conformity the instructions provided in the Ford Truck Shop Manual should
with this Standard. not adversely affect the compliance of a completed vehicle to
Standards 212 and 219.

STATEMENTS OF CONFORMITY 38 E-SERIES (May, 2003)

212/ The statement below is applicable to the following 214 The statement below is applicable to the following
219 incomplete vehicle types if the GVWR is 4536 kg incomplete vehicle types if the GVWR is 4536 kg
[10,000 lb] or less: [10,000 lb] or less:
• E-Series Basic (Stripped) Chassis • E-Series Basic (Stripped) Chassis
The Basic (Stripped) Chassis is designed by Ford The Basic (Stripped) Chassis is designed by Ford
Motor Company to be completed as a walk-in van type Motor Company to be completed as a walk-in-van type
vehicle. Walk-in vans are exempt from the requirements vehicle. Walk-in vans are exempt from the requirements
of Standard 212, Windshield Mounting, and Standard of Standard 214, Side Impact Protection. See walk-in
219, Windshield Zone Intrusion. van definition on page 8.
212/ Canadian Requirements: 217 The statements below are applicable to the incomplete
219 The preceding statements for FMVSS 212/219 are E-Series Van or Wagon when completed as a bus
appropriate compliance representations for CMVSS 212, (not school bus):
Windshield Mounting, and CMVSS 219 Windshield Zone This vehicle, when completed, will conform to Standard
Intrusion, if this incomplete vehicle was manufactured 217, Bus Window Retention and Release, if no
for sale or use in Canada. In such a case, CMVSS 212 alterations, modifications, or replacements are made to
and 219 paragraphs (5.1) and (8) are substituted for the doors, window glazing materials, window mounting
the reference to FMVSS 212 and 219 Sections 6.1(b) systems, or the surrounding door structure as provided
and 7.7(b) respectively. by Ford Motor Company.
213 The statement below is applicable to all incomplete Any windows, doors, additional components, or
vehicle types: emergency exits added to this vehicle must meet the
Conformity with Standard 213, Child restraint systems, is requirements of this Standard.
not substantially affected by the design of the incomplete 217 The statement below is applicable to the Cutaway
vehicle; accordingly Ford Motor Company makes no when completed as a bus (including school bus):
representation as to conformity with this Standard. Any
child restraint system that is added or incorporated Conformity with Standard 217, Bus Window Retention
into the design of a designated seating position must and Release, is not substantially affected by the design
conform to the requirements of this standard. of this incomplete vehicle; accordingly Ford Motor
Company makes no representation as to conformity with
214 The statements below are applicable to the following this Standard other than that the front door windows will
vehicle types if the GVWR is 4536 kg [10,000 lb] or comply with the s5.1 requirements of this Standard if
less: no modifications, alterations, or replacements are made
• Chassis Cab to the window glazing materials, window mounting
• Incomplete E-Series Van or Wagon system,or the surrounding door structure as provided
by Ford Motor Company.
This vehicle, when completed, will conform to Standard
214, Side Impact Protection, if: 217 Canadian Requirements:
• No alterations, modifications, or replacements are The preceding statements for FMVSS 217 are
made to the door, surrounding door structure, door appropriate compliance representations for CMVSS
hinges, door latches and strikers, or any attaching 217, Bus Emergency Exit and Window Retention
hardware as provided by Ford Motor Company. and Release, when a vehicle is completed as a Bus
• The Incomplete E-Series Van or Wagon roof or (not School Bus) and if this incomplete vehicle was
window modifications do not exceed the defined cut manufactured for sale or use in Canada. In such a case,
out areas shown in the Figures on pages 34, 35, and CMVSS 217 paragraphs (2) and (2.1) are substituted
36, respectively. for the reference to FMVSS 217 Section 5.1. When
an E-Series Cutaway is completed as a School Bus,
214 The statements below are applicable to the E-Series Ford Motor Company makes no representation as to
Cutaway if the GVWR is 4536 kg [10,000 lb] or less: conformity to this Standard.
This vehicle, if equipped with both front doors as
manufactured by Ford Motor Company when completed,
will conform to Standard 214, Side Impact Protection,
if no alterations, modifications, or replacements are
made to the door, surrounding door structure, the
entire roof structure, door hinges, door latches and
strikers, or any attaching hardware provided by Ford
Motor Company.
This vehicle if equipped with a driver-side door only
when completed, will conform to Standard 214, Side
Impact Protection, for that door only if no alterations,
modifications, or replacements are made to the door,
surrounding door structure, the entire roof structure,
door hinges and strikers, or any attaching hardware
provided by Ford Motor Company.
Any side door and surrounding body structure added to
this vehicle, if a designated seating position is less than
254 mm [10 in] inboard of that door, must conform to
the requirements of this standard.

E-SERIES (May, 2003) 39 STATEMENTS OF CONFORMITY

219 See combined statements under “212/219” for all 225 The statement below is applicable to all incomplete
vehicle types. vehicle types if the GVWR is 3856 kg [8,500 lb] or less,
220 The statements below are applicable to the Cutaway except Basic Stripped Chassis. It is also applicable to
equipped with the School Bus Prep Package when buses (including school buses) with a GVWR of 4536
completed as a school bus: kg [10,000 lb] or less:
The Cutaway body structure as manufactured by Ford, This vehicle, when completed, will conform to Standard
does not meet the strength requirements of FMVSS 220, 225, Child Restraint Anchorage Systems, if:
School Bus Rollover Protection; accordingly Ford Motor • No alterations are made to the front passenger seat
Company makes no representation as to conformity of tether anchorages or LATCH lower anchors, and
the completed vehicle with this Standard. access to the anchorages is not restricted, and
no alterations are made to the seat assemblies,
221 The statements below are applicable to the Cutaway
their anchorages, the floor pan, or floor pan
equipped with School Bus Prep Package when
reinforcements.
completed as a school bus:
• For the incomplete E-Series Van and Cutaway with
This vehicle when completed, will conform to Standard
no front seats, if a forward facing front passenger
221, School Bus Body Joint Strength, if;
seat is installed and there are no additional seating
• No alterations or modifications are made to the rows, it must have the required tether anchor and
body panel joints as manufactured by Ford Motor LATCH lower anchors.
Company from the forwardmost point of the windshield
• For the incomplete E-Series Van and Cutaway,
rearward.
completed with not more than two seats to the rear
• The passenger first row seating reference point is of the front row, the forward facing rear seats must
located 762.0 mm [30.00 inch] or more, rearward of have the required tether anchor, and a pair of LATCH
the back of the Cutaway body. lower anchors.
Any additional maintenance panels or body panel joints • For the incomplete E-Series Van and Cutaway,
that are added to this vehicle must comply with the completed with three or more forward facing seats to
requirements of this regulation. the rear of the front seats, at least three of the forward
222 The statement below is applicable to the Cutaway facing rear seats must have the required tether, and
equipped with the School Bus Prep Package when two of those seats must also have a pair of LATCH
completed as a school bus: lower anchors. If at least one of the forward facing
rear seats is not outboard, at least one non-outboard
Conformity with Standard 222, School Bus Passenger
forward facing seat must have a tether. If the vehicle
Seating and Crash Protection, is not substantially affected
has at least three rows of forward facing seats, at
by the design of this incomplete vehicle; accordingly
least one of the forward facing seats in the second
Ford Motor Company makes no representation as to
row must have the tether anchor and a pair of LATCH
conformity with this Standard.
lower anchors.
225 The statement below is applicable to the following
incomplete vehicle types:
• E-Series Basic (Stripped) Chassis
Conformity with Standard 225, Child Restraint
Anchorage Systems, is not substantially affected by
the design of this incomplete vehicle; accordingly,
Ford Motor Company makes no representations as to
conformity with this Standard.

STATEMENTS OF CONFORMITY 40 E-SERIES (May, 2003)

301 Note
CONNECTOR HOUSING
RETENTION CLIP
The terms “body” or “body structure”, in the 301 DO NOT REINSTALL
ALWAYS USE A NEW
SPACER

statements that follow include not only the basic body RETENTION CLIP.

or body structure but also any equipment permanently

attached to that body or body structure installed by the ORINGS
(2 PLACES)

subsequent stage manufacturer.

301 INFORMATION WARNING
BEFORE OPENING THE FUEL SYSTEM
ON VEHICLES WITH EFI ENGINES,
The Unloaded Vehicle Weight of the completed vehicle PUSH UNTIL CLICKS
RELIEVE FUEL PRESSURE BY
may significantly affect its capability to meet the FOLLOWING THE INSTRUCTIONS IN
THE FORD TRUCK SHOP MANUAL FOR
requirements of FMVSS 301. Completed vehicles THE APPROPRIATE MODEL AND
MODEL YEAR.
manufactured by Ford that are tested to demonstrate
compliance with FMVSS 301 are loaded pursuant to PULL TO VERIFY CONNECTION
FUEL PUSH-CONNECT INSTALLATION
INSTRUCTIONS
s7.1 .6 of the Standard. The test weights of these TO INSTALL THE FITTING ONTO THE
TUBE, ALIGN THE FITTING AND THE
vehicles comprise the Unloaded Vehicle Weights TUBE AXIALLY AND PUSH THE
including the weights of all available regular production FITTING ONTO THE TUBE END.
WHEN THE FITTING IS ENGAGED, A
options plus the loads specified by s7.1.6. These test DEFINITE CLICK WILL BE HEARD.
FUEL PUSHCONNECT PULL ON FITTING TO MAKE SURE IT
weights are less than the respective designated Gross INSTALLATION INSTRUCTIONS
IS FULLY ENGAGED.
Vehicle Weight Ratings. In addition to the specific
statements below, refer to the Design Recommendation FIGURE H - NYLON FUEL LINE PUSH-CONNECT
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 REMOVAL TOOL
second unit bodies and their attachments to be
compatible with E-Series vehicles.
301 In addition to the statements pertaining to particular
incomplete vehicle types which follow on pages
41-53, the statements immediately below, concerning RETAINER - FUEL TUBE
PUSH CONNECTOR
Standard 301 Fuel System Integrity, apply to all
incomplete vehicle types to be completed with a E-SERIES:
SUPPLY - E9UA-9J278-AA
GVWR of 4536 kg [10,000 lb] or less or equipped RETURN E9UA-9J278-BA
with School Bus Prep Package and completed as
a school bus. REMOVAL TOOL

• If the push connectors on nylon fuel lines are WARNING

disconnected, they must be reconnected as shown in BEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITH
EFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWING
Figure H on this page and the retention clip must be THE INSTRUCTIONS IN THE FORD TRUCK SHOP MANUAL
FOR THE APPROPRIATE MODEL AND MODEL YEAR.
discarded and replaced with a new clip as specified
in Figure H. FIGURE J - FLEXIBLE FUEL LINE PUSH-CONNECT
• The special removal tool shown in Figure J on
this page must be used to open push connectors 301 The statements below are applicable to the following
installed on steel fuel lines if the lines need to be incomplete vehicle types if the vehicle GVWR is 4536
disconnected. The Ford Service Manual will reference kg [10,000 lb] or less:
the appropriate tool that is available from Ford
Customer Service Division. • Incomplete E-Series Van or Wagon
• The push connectors on flexible fuel lines, if This vehicle, when completed, will conform to Standard
disconnected, must be reconnected by snapping 301, Fuel System Integrity, if:
them back into position and installing the appropriate • The following fuel system components, as installed
Retainer as shown in Figure J on this page. by Ford Motor Company, are not to be removed,
• When welding near fuel system components, all relocated, altered, or modified in any way:
metallic components must be adequately shielded – Fuel tank and attachment hardware, including
and protected from heat or weld splatter. All non- sending unit, vapor valve, fuel tank shield and
metallic components must be removed. in-tank electric fuel pump (all gasoline engine
applicatons), and OBD II pressure transducer
– Fuel filler cap, pipe, hose, and attachment
hardware
– Fuel lines, routing, and attachments
– Vapor lines and carbon canister - (gasoline engine
application)
– Fuel pump
– Fuel filter
– Fuel water separator fuel filter/primer, fuel line
heater, and injection pump - (diesel engine only)
NOTE: Some incomplete vehicles are equipped with
nylon fuel tubes. In the event that the tubes require – Fuel shut off switch (Inertia switch)
repair or replacement, only Ford approved parts
or their equivalents should be used.
301 (Continued Next Page)

E-SERIES (May, 2003) 41 STATEMENTS OF CONFORMITY

 OUTBOARD
FRAME REINFORCEMENT

BACK-TO-BACK
CROSSMEMBERS

OUTBOARD
FRAME REINFORCEMENT

LOWER FRAME
FLANGE REINFORCEMENTS

FIGURE I - E-SERIES CUTAWAY WITH GASOLINE ENGINE AND SCHOOL BUS PREPARATION PACKAGE

301 (Continued)
• No other alteration or modification made to the – Fuel lines, routing, and attachments
incomplete vehicle, as manufactured by Ford Motor – Vapor line(s) and carbon canister - (gasoline engine
Company, and no other components or structure application)
installed by a subsequent stage manufacturer result
– Fuel pump
in penetration, separation, or other damage to the
fuel system or any portion thereof when the vehicle – Fuel filter
is tested in any manner specified by applicable – Fuel water separator fuel filter/primer, fuel line
provisions of Standard 301.† heater, and injection pump - (diesel engine only)
• The completed vehicle’s Unloaded Vehicle Weight – Fuel shut off switch (Inertia switch)
does not exceed the value designated in Table A for – The two Outboard Frame Reinforcements, two
E-Series on page 15 corresponding to the incomplete Lower Frame Flange Reinforcements, and two extra
vehicle’s model and wheelbase. back-to-back crossmembers, all shown above,
301 The statements below are applicable to the following and all unique to the gasoline engine School Bus
incomplete vehicle types if the vehicle GVWR is Package.
4536 kg [10,000 lb] or less: • No other alteration or modification made to the
• Cutaway incomplete vehicle as manufactured by Ford Motor
• E-Series Cutaway (SRW) with Diesel Engine Company and no other components or structure
and School Bus Preparation Package installed by a subsequent stage manufacturer result
• E-Series Cutaway (SRW) with Gasoline Engine in penetration, separation, or other damage to the
and School Bus Preparation Package fuel system or any portion thereof when the vehicle
is tested in any manner specified by applicable
This vehicle, when completed, will conform to Standard provisions of Standard 301.†
301, Fuel System Integrity, if: • The completed vehicle’s Unloaded Vehicle Weight
• The following fuel system components as installed does not exceed the value designated in Table A on
by Ford Motor Company are not removed, relocated, page 15 corresponding to the model and wheelbase.
altered, or modified in any way except as specified in
the following representations:
– Fuel tank(s) and attachment hardware, including 301 (Continued Next Page)
sending unit, vapor valve, fuel tank shield, pressure
transducer, and in-tank electric fuel pump
– Fuel filler cap(s), pipe(s), hose(s), and attachment
hardware

† 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 42 E-SERIES (May, 2003)

301 (Continued) 301 The statements below are applicable to the following
incomplete vehicle types if the GVWR Is 4536 kg
• The body installed by a subsequent stage [10,000 lb] or less:
manufacturer and the Ford installed fuel system • E-Series Basic (Stripped) Chassis
components are located and mounted as follows:
Conformity with Standard 301, Fuel System Integrity, is
– The body is mounted securely and is so designed not substantially affected by the design of this incomplete
that when the completed vehicle is tested in any vehicle; accordingly Ford Motor Company makes no
manner specified by applicable provisions of representation as to conformity with this standard.
Standard 301,
However, Ford Motor Company has tested completed
(a) body components do not contact any fuel vehicles incorporating a representative fuel system
system component at any time (other than at and frame assembly of a Basic (Stripped) Chassis in
the points where the fuel system is permanently accordance with the procedures of Standard 301 at
attached to the body), and, test weights specified by s7.1.6 of the Standard. The
(b) body deformation or movement relative to tested vehicles met the applicable requirements of
the frame does not cause any fuel system Standard 301. This vehicle, when completed, is capable
component to be penetrated, disconnected, or of compliance with FMVSS 301, if:
otherwise damaged. • The following fuel system components as installed
– The rear end of the body (excluding the by Ford Motor Company are not removed, relocated,
rear bumper) installed by a subsequent stage altered, or modified in any way except as specified in
manufacturer does not extend beyond (overhang) the following representations:
the rear edge of the vehicle frame or frame – Fuel Tank and attachment hardware, including
extension. Any extension of the vehicle frame must sending unit, vapor valve, OBD II pressure
be constructed and attached so as to perform transducer, fuel tank shield, and in-tank electric
as a continuation of the vehicle frame when the pump
completed vehicle is tested in any manner specified
by applicable provisions of Standard 301. – Fuel filler cap, pipe, hose(s), and attachment
hardware
– The fuel filler cap(s), pipe(s), hose(s) and
attachment hardware are installed as shown – Fuel lines, routing, and attachments
in Figure K page 44 for E-Series vehicles. All – Vapor line(s) and carbon canister
components must be securely retained to remain – Fuel Filter
intact when the completed vehicle is tested in
• No other alteration or modification is made to the
any manner specified by applicable provisions of
incomplete vehicle, as manufactured by Ford Motor
Standard 301.
Company, and no other components or structure
installed by a subsequent stage manufacturer result
in penetration, separation, or other damage to the
fuel system or any portion thereof when the vehicle
is tested in any manner specified by applicable
provisions of Standard 301.†
• The completed E-Series has an Unloaded Vehicle
Weight that does not exceed the value designated
in Table A on page 15 corresponding to the model,
and wheelbase.

† Temporary removal of the front bumper and front bumper mounting

system during manufacture, and reinstallation in accordance
with the instructions provided in the Ford Truck Shop Manual,
should not adversely affect compliance of the completed vehicle
to Standard 301.

E-SERIES (May, 2003) 43 STATEMENTS OF CONFORMITY

 • The body installed by a subsequent stage • The E-Series Basic (Stripped) Chassis aft-of-axle fuel
manufacturer and the Ford installed fuel system filler cap, pipe, hose(s), and attaching hardware are
components are located and mounted as follows: installed as shown in Figure K, below. All components
– The body is mounted securely and is so designed must be securely retained to remain intact when the
that when the completed vehicle is tested in any completed vehicle is tested in any manner specified
manner specified by applicable provisions of by applicable provisions of Standard 301.
Standard 301, The Basic (Stripped) Chassis is equipped with a Fuel
(a) body components do not contact any fuel Shutoff Switch. The switch is located on the column
system component at any time (other than at support structure for E-Series and must not be relocated,
the points where the fuel system is permanently altered, or modified in any way.
attached to the body), and,
(b) body deformation or movement relative to
the frame does not cause any fuel system
component to be penetrated, disconnected, or
otherwise damaged.
• The rear end of the body (excluding the rear bumper)
installed by a subsequent stage manufacturer does 301 (Continued on Page 45)
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.

TO CL OF REAR CL OF FILLER NECK

AXLE FOR
STRIPPED CHASSIS OUTBOARD SURFACE
TO BACK OF ALL W.B.
601.4 + 12.7 OF FRAME RAIL
CUTAWAY CAB [23.7 + 0.5]

FRONT OF
VEHICLE 2641.6 [104.0] [+0.00-2.00] [138 wb]
3149.6 [124.0] [+0.00-2.00] [158 wb]
3606.8 [142.0] [+0.00-2.00] [178 wb]

733.4
[28.875]
(MAX.)
SCREW 3 REQ’D.
TORQUE TO 2.1- 2.9 Nm NOTES:
18 - 26 IN.-LB.
TORQUE ALL WORM GEAR DRIVEN
HOSE CLAMPS TO 2.9 - 4.3 NM
25 - 38 IN.-LB.
TOP OF FUEL TANK
FILLER [ ] DIMENSIONS ARE INCHES
PIPE
SUPPORT
319.0 * SECURE WITH TIE
[12.56] STRAPS AS REQUIRED CRITICAL CONTROL ITEM
TO VENT HOSE

* FILLER HEIGHT FOR NATURAL GAS IS

416.0 [16.38].
CALIFORNIA FILLER HEIGHT FOR SCHOOL BUS
POINT Z FUEL SYSTEM 416.0 [16.38].
SEE PAGE 58

FUEL TANK
FILL PIPE

N611131-S36 ROUTE FILL AND VENT

M4 SELF-TAPPING HOSE SO NO LOW
SCREW SPOTS OCCUR

9A099
40.2 GROUND STRAP
N611645-S36 [1.583]
FUEL TANK
M10 SELF-TAPPING SCREW
(ATTACH TO SOUND EXISTING 9.7 DIA. HOLES
METAL ON FRAME) (USED FOR EXHAUST
ON R.H. SIDE)
E-SERIES E-350/450 CUTAWAY AND BASIC (STRIPPED)
CHASSIS AFT-OF-AXLE FUEL FILLER SYSTEM

FIGURE K - E-SERIES CUTAWAY, CHASSIS CAB AND BASIC (STRIPPED) CHASSIS FUEL FILLER PIPE INSTALLATION

STATEMENTS OF CONFORMITY 44 E-SERIES (May, 2003)

301 (Continued) 301.2 Canadian Requirements for all incomplete vehicle
301 The statements below are applicable to the over 4536 types if the GVWR is 4536 kg [10,000 lb] or less:
kg [10,000 lb] GVWR E-350 DRW and E-450 Super The statement for Standard 303 is an appropriate
Duty Cutaway when equipped with Diesel Engine compliance representation for CMVSS 301.2, CNG
and School Bus Prep Package and completed as Fuel System Integrity, if the incomplete vehicle was
a school bus: manufactured for sale or use in Canada.
This vehicle when completed will conform to Standard 301.2 Canadian Requirements for the E-450 Cutaway
301, Fuel System Integrity if: with the dedicated Compressed Natural Gas (CNG)
• The following fuel components as installed by Ford package:
Motor Company are not removed, altered, or modified The E-450 Cutaway with the dedicated CNG package
in any way except as specified in the following will meet all of the requirements of Standard 301.2,
representations: CNG Fuel Systems Integrity, provided:
– Fuel tank and attachment hardware, including • The fuel tanks, fill valves, fuel lines, and shields as
sender unit, vapor valve, and fuel tank shield installed by Ford Motor Company, are not altered or
– Fuel filler cap, pipe, hoses, and attaching moved in any way.
hardware • The fuel filler is located in accordance with Figure
– Fuel pump K, page 44 (which has been drawn for a gasoline
fuel system, but the filler location for natural gas
– Fuel filter is noted).
– Fuel water separator, fuel filter/primer, fuel line In addition, the E-450 Cutaway with the CNG package
heater, and injection pump has been designed to allow two additional tanks to be
– Fuel shut-off switch (Inertia switch) installed in the body. With body mounted fuel tanks,
– The two lower frame brackets on E-350 DRW compliance with Standard 301.2 is not substantially
affected by the design of this incomplete vehicle;
• The completed vehicle when loaded to the
accordingly, if tanks are added, Ford Motor Company
requirements of S7.1.6 (c) does not exceed the
makes no representation as to conformity with this
GVWR or GAWR’s.
standard.
• The E-350 DRW and E-450 floor structure of the
Second Unit Body and rear bumper are manufactured 302 The statement below is applicable to all incomplete
and installed to the specifications found in the Figures vehicle types except the Basic (Stripped) Chassis:
on pages 46 and 47 . This vehicle, when completed, will conform with
• The fill hoses, hose clamps, ground strap, and fuel Standard 302, Flammability of Interior Materials, if no
sender unit must be installed to the specification on alterations are made to those components covered
Figure K, page 44. by the Standard which are installed by Ford Motor
Company and all components covered by Standard
• No other alteration or modification made to the 302, which are added to the incomplete vehicle by
incomplete vehicle as manufactured by Ford Motor subsequent stage manufacturers meet the flammability
Company and no other components or structure requirements of the Standard.
installed by a subsequent stage manufacturer result
in penetration, separation, or other damage to the 302 The statement below is applicable to the following
fuel system or any portion thereof when the vehicle incomplete vehicle types:
is tested in any manner specified by applicable • E-Series Basic (Stripped) Chassis
provisions of Standard 301.† Conformity with Standard 302, Flammability of Interior
301 Canadian Requirements: Materials, is not substantially affected by the design
of this incomplete vehicle; accordingly Ford Motor
The Canadian loading requirements are provided in
Company makes no representation as to conformity
Section 3.3 of Test Method 301 Fuel System Integrity,
with this Standard. However, Ford Motor Company
revised: February 8, 2001, and should be substituted
does represent that the items covered by Standard 302
wherever references to FMVSS 301 Section 7.1.6,
when provided, are manufactured to conform to the
loading requirements have been made in the statements
requirements of Standard 302.
of conformity for standard 301.

† Temporary removal of the front bumper and front bumper mounting

system during manufacture and reinstallation in accordance
with the instructions provided in the Ford Truck Shop Manual
should not adversely affect compliance of the completed vehicle
to Standard 301.

E-SERIES (May, 2003) 45 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 R.H. 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 & FOURTH CROSS 1.9mm [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 L.H. 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 R.H. 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

BLIND RIVET FASTENERS

The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength
of 3600 lb and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.
PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION
Item 5 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –
Item 6 to 15 48 Estimated 50.8mm [2.00] stagger frt and rr 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 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

1318.3 12.0mm BOLT (6 REQ’D) [1.00]
[51.90] TORQUE 70Nm 52 ft lb 16 TYPICAL
778.8 2375.0
[30.66] [93.5] MINIMUM 268.0
161.4
[6.35] 9 164.3 [10.55]
9 [6.47]
7 2
12.8
[.50] 6 8
5 9 1 147.8
7 [5.82] 163.8
[6.45]
11
8 15
THE FUEL FILE HOLE
IN ITEM #15 (FLOOR) MUST BE 3.0 [.12]
114.5 LARGER THEN BASE OF ITEM #16
9
[4.50] 4
3 10
1/2 BOLT GR5 , 1/2 NUT GR5
TORQUE 95Nm 70 ft lb
MAY BE REMOVED
TO ACCOMMODATE 8 2438.4 1/2 WASHER
WHEELHOUSE [96.00] (HARDENED)
357.1 14.0 x 28.0
CLEARANCE [14.06] 2 PER BOLT [.55 x 1.10] MAX
2 SLOTS IN ITEM
12 #12,13,& 14

14
241.3
[9.50] 13

162.1
[6.38]

EXISTING SLOT 101.6

[4.00]
EXISTING 50.8
FRAME 228.6
[2.00]
HOLES [9.00]

FORD PROVIDED
ISOLATORS (6)

FIGURE P1 - E-Series School Bus FUEL SYSTEM AND FLOOR STRUCTURE

STATEMENTS OF CONFORMITY 46 E-SERIES (May, 2003)

 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
7
THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN
COMPLETED.
36.1
[ 1.42 ]
71.6
[ 3.13 ]
851.6
[ 33.53 ]

CL RAIL
C
425.8
[ 16.76 ]
134.0
[ 5.28 ]
13.0
[ 0.51 ] DIA 8 HOLES 6
170.0 32.1 42.7
5 [ 6.69 ] [ 1.26 ] [ 1.68 ] 40.3
[ 1.59 ]
36.7
85.0 [ 1.44 ] 170.0
[ 3.35 ] [ 6.69 ]
74.0 122.0
[ 2.91 ] 26.9 [ 4.80 ]
37.0 [ 1.06 ] 48.0 32.6
110.0 98.0 125.0 [ 1.89 ] 18.0 [ 1.28 ] 138.8
[ 1.46 ] [ 3.86 ] [ 4.92 ] 110.0
[ 4.33 ] [ 0.71 ] [ 5.46 ]
[ 4.33 ]
C 172.0
C
L L [ 6.77 ]
CL
SEE VIEW C FOR 28.1 C
L 34.9
HOLE DIMENSIONS
[ 1.11 ] 3 [ 1.37 ] 4
46.5 38.6
LOCATION 13.0 [ 1.52 ] 13.0
[ 1.83 ] [ 0.51 ] DIA 4 HOLES [ 0.51 ] DIA 4 HOLES
14.0 [.55] DIA HOLE M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.
M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.

985.6
C
[ 38.80 ] TO L OF 36.0 DIA HOLE 102.2
[ 4.02 ]

492.8 36.0
C
[ 19.40 ] TO L OF SILL [ 1.42 ] DIA 2 HOLES
200.0
42.7 [ 7.87 ]
[ 1.68 ]

320.0
[ 12.60 ]

134.0 8.0
[ 5.28 ]
49.2 [ 0.31 ] 1318.3
[ 1.94 ] 46.8 [ 51.90 ]
67.0 13.0 [ 1.84 ]
[ 2.64 ] [ 0.51 ] DIA 8 HOLES
SUPPORT CROSS SILL OUTER L.H. SHOWN.
10 R.H. SYMETRICALLY OPPOSITE.
VIEW C

TRIM WITH 45 o ANGLE

TO REMOVE SHARP CORNER
1303.1 571.7
1168.4
[ 51.30 ] [ 22.51 ]
[ 46.00 ]
CL 24.8
[ 0.98 ]

552.4
[21.78] 44.5
46.2 [ 1.75 ] 9
[ 1.82 ]
23.1
CL [ 0.91 ] 177.5
1 [ 6.99 ]

15.0 409.3 WELD SHEET METAL

[ 0.59 ] [ 16.11 ] RELIEF AFTER FORMING
ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2
ON ALL 4 EDGES. 104.8
[ 4.13 ]
B SUPPORT BODY IS0LATOR TO CROSS
SILL L.H.SHOWN. R.H. SYMETRICALLY GUSSET CROSS SILL TO
OPPOSITE. OUTER SUPPORT R.H. SHOWN
L.H. SYMETRICALLY OPPOSITE.

A
95.5
[ 3.76 ]
56.1
[ 2.21 ]

CL

102.0 60.4
[ 4.02 ] [ 2.38 ] 14.0 DIA 3 HOLES
111.1 [ 0.55 ]
[4.37]

VIEW B VIEW A

IVM0028

FIGURE P2 - E-SERIES DIESEL SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE

E-SERIES (May, 2003) 47 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 R.H. 6.35mm [0.25] HRLC STEEL 1
3 BRACKET SPACER FOR ISOLATOR SUPPORT TO FRONT CROSS SILL 6.35mm [0.25] HRLC STEEL 2
4 BRACKET SPACER FOR ISOLATOR SUPPORT TO SECOND 6.35mm [0.25] HRLC STEEL 2
L L I S S S OR C
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 & FOURTH CROSS 1.9mm [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 L.H. 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 R.H. 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

BLIND RIVET FASTENERS

The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength
of 3600 lb and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION

Item 5 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –
50.8mm [2.00] stagger frt and rr flange
Item 6 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –
50.8mm [2.00] stagger frt and rr 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 crosssill
Item 7 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of crosssill
Items 8 or 9 to Items 10 or 11 3 on vertical side of item 10 or 11, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers
Items 16 50.8mm [2.00] Centers

25.4
[1.00]
FORD PROVIDED 16 TYPICAL
12.0mm BOLT (6 REQ’D)
1318.3 TORQUE 70Nm 52 ft lb
182.4
[51.90] [7.18] 298.5
2375.0 [11.75]
747.5 [93.5] MINIMUM
[29.43]
9
118.27
9 [4.65]
203.3 182.0
7 2 [8.00] [7.16]
275.8 8
[10.86] 6 9
12.8 5 1
[0.50]
7
11
THE FUEL FILL HOLE 15
8 IN ITEM #15 (FLOOR) MUST BE 3.0 [.12]
LARGER THEN BASE OF ITEM #16
10
114.5
[4.50] 9
4 1/2 BOLT GR5 , 1/2 NUT GR5
TORQUE 95Nm 70 ft lb

MAY BE REMOVED
3 14.0 x 28.0
TO ACCOMMODATE [.55 x 1.10] MAX
14 2 SLOTS IN ITEM
WHEELHOUSE 357.1 #12,13,& 14
CLEARANCE 9 [14.06] 2438.4
[96.00] 1/2 WASHER
(HARDENED)
2 PER BOLT
241.3
[9.50]

3162.3 162.1 13
[124.5] [6.38]
TO BACK
OF
CUTAWAY
BODY

12
50.8
228.6 101.6 [2.00]
[9.00] [4.00]
416.0
[16.38] ADD SLOT AND HOLES DIMENSIONALLY
SIMILAR TO THOSE SUPPLIED AT
TO REAR OF FORD SUPPLIED FRAME RAIL.
TOP
OF FRAME FRAME EXTENSION

FORD PROVIDED FRAME REINFORCEMENT

ISOLATORS (6)

FIGURE P3 - E-SERIES SCHOOL BUS CNG FUEL SYSTEM AND FLOOR STRUCTURE – AFT AXLE –
158 AND 176 INCH WHEELBASE

STATEMENTS OF CONFORMITY 48 E-SERIES (May, 2003)

 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
7
THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN
COMPLETED.
36.1
[ 1.42 ]
71.6
[ 3.13 ]
851.6
[ 33.53 ]

CL RAIL
C
425.8
[ 16.76 ]
134.0
[ 5.28 ]
13.0
[ 0.51 ] DIA 8 HOLES 6
170.0 32.1 42.7
5 [ 6.69 ] [ 1.26 ] [ 1.68 ] 40.3
[ 1.59 ]
36.7
85.0 [ 1.44 ] 170.0
[ 3.35 ] [ 6.69 ]
74.0 122.0
[ 2.91 ] 26.9 [ 4.80 ]
37.0 [ 1.06 ] 48.0 32.6
110.0 98.0 125.0 [ 1.89 ] 18.0 [ 1.28 ] 138.8
[ 1.46 ] [ 3.86 ] [ 4.92 ] 110.0
[ 4.33 ] [ 0.71 ] [ 5.46 ]
[ 4.33 ]
C 172.0
C
L L [ 6.77 ]
CL
SEE VIEW C FOR 28.1 C
L 34.9
HOLE DIMENSIONS
[ 1.11 ] 3 [ 1.37 ] 4
46.5 38.6
LOCATION 13.0 [ 1.52 ] 13.0
[ 1.83 ] [ 0.51 ] DIA 4 HOLES [ 0.51 ] DIA 4 HOLES
14.0 [.55] DIA HOLE M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.
M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.

102.2
985.6 C [ 4.02 ]
[ 38.80 ] TO L OF 36.0 DIA HOLE

492.8 36.0
C
[ 19.40 ] TO L OF SILL [ 1.42 ] DIA 2 HOLES
200.0
42.7 [ 7.87 ]
[ 1.68 ]

320.0
[ 12.60 ]

134.0 8.0
[ 5.28 ] [ 0.31 ] 1318.3
49.2
[ 1.94 ] [ 51.90 ]
46.8
67.0 13.0 DIA 8 HOLES [ 1.84 ]
[ 2.64 ] [ 0.51 ] SUPPORT CROSS SILL OUTER L.H. SHOWN.
10 R.H. SYMETRICALLY OPPOSITE.
VIEW C

TRIM WITH 45 o ANGLE

TO REMOVE SHARP CORNER
1303.1
1168.4 571.7
[ 51.30 ] [ 22.51 ]
[ 46.00 ]
CL 24.8
[ 0.98 ]

552.4
[21.78] 44.5
46.2 [ 1.75 ] 9
[ 1.82 ]

CL 23.1
177.5
1 [ 0.91 ]
[ 6.99 ]
15.0 409.3 WELD SHEET METAL
[ 0.59 ] [ 16.11 ] ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2 RELIEF AFTER FORMING
ON ALL 4 EDGES.
104.8
[ 4.13 ]
B SUPPORT BODY IS0LATOR TO CROSS
SILL L.H.SHOWN. R.H. SYMETRICALLY GUSSET CROSS SILL TO
OPPOSITE. OUTER SUPPORT R.H. SHOWN
L.H. SYMETRICALLY OPPOSITE.

95.5
[ 3.76 ]
56.1
[ 2.21 ]

CL

111.1 102.0 60.4

[ 4.02 ] [ 2.38 ] 14.0 DIA 3 HOLES
[4.37] [ 0.55 ]

VIEW B VIEW A

FIGURE P4 - E-SERIES CNG SCHOOL FLOOR STRUCTURE – AFT AXLE - 158 AND 176 INCH WHEELBASE

E-SERIES (May, 2003) 49 STATEMENTS OF CONFORMITY

 ITEM PART NAME MATERIAL QUANTITY
1 SUPPORT RAIL R.H. 6.35mm [0.25] HRLC STEEL 1
2 SUPPORTRAIL L.H. 6.35mm [0.25] HRLC STEEL 1
3 RISER BRACKET 6.35mm [0.25] HRLC STEEL 6
4 FRONT CROSS 1.9mm [0.075] HRLC STEEL 3
5 MIDDLE CROSS 1.9mm [0.075] HRLC STEEL 2
6 GUSSET L.H. 1.9mm [0.075] HRLC STEEL 5
7 GUSSET R.H. 1.9mm [0.075] HRLC STEEL 5
8 OUTER SUPPORT 3.0mm [0.120] HRLC STEEL 2
9 FLOOR (NOT SHOWN) 1.9mm [0.075] HRLC STEEL 1

BLIND RIVET FASTENERS

The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength of 3600 lb
and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION

Items 4 to Items 9 48 Estimated 101.6mm [4.00] centers on frt and rr flange –
50.8mm [2.00] stagger frt and rr flange
Items 4 or 5 to Items 6 or 7 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
Items 6 or 7 to Items 8 3 on vertical side of item 8, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers

490.3
1254 2375.0
1800 [19.3]
[49.4] [93.5]
[70.9]
6
6 4
4 5
5 6 FORD PROVIDED
M12 BOLT (8 REQ’D)
7 6 TORQUE 70Nm 52 ft lb

3
2

4 7
7
7
3 6 7
1

FORD PROVIDED
ISOLATORS (6)

IVM176MID

FIGURE P5 - E-SERIES CNG MIDSHIP TANK SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE -
176 INCH WHEELBASE

STATEMENTS OF CONFORMITY 50 E-SERIES (May, 2003)

 BOTH ENDS OF ITEMS #4 AND #5 CROSS SILLS MUST BE
WELDED COMPLETELY TO ITEM #8 LEFTSIDE AND ITEM #11
RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDS
THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN
COMPLETED.

172
C
[6.77] 691.7 2369
141.3 [27.23] [93.27]
985.6
[5.56] [38.8]

39.2
68.4 [1.54] 4 PLACES
[2.69]
36.1 4
[1.42]
67 TYP
[2.64] O
45 2 PLACES
14
[.55] DIA
43.8
5 [1.72]
2 PLACES

10
[.39]
134 2 PLACES
O [5.28]
45 2 PLACES TYP
2369
[93.27] 43.8 110
[1.72] [4.33]
2 PLACES 30.7
42.7 42.2
[1.68] [1.27]
CL [1.66]
10
[.39] CL
3
2 PLACES
134
[5.28] SEE VIEW C FOR
HOLE DIMENSIONS
41.7 LOCATIONS
[1.64]
128.3 67
FRONT OF VEHICLE [5.05] [2.64] M12 BOLT & NUT GC 10.9
65.4 (24 REQ’D)
[2.57]
2 PLACES 13 TORQUE 70 Nm 52 ft. lb.
170 [.51] DIA
[6.69] 4 HOLES

985.6 TO CL OF 36.0 DIA HOLE

[38.8]

36 36.0 DIA 2 HOLES

[1.42] 1800
[70.87]
13 DIA 8 HOLES
[.51]
42.7
[1.68]
200
[7.87]

46.8 8
134 TYP 21.4 [1.84]
[5.28] 86 [.84]
3.39
67 TYP
[2.64]
FRONT OF VEHICLE SUPPORT CROSS SILL OUTER L.H. SHOWN.
FRONT OF VEHICLE
R.H. SYMETRICALLY OPPOSITE.
VIEW C
TRIM WITH 45 ANGLE
TO REMOVE SHARP CORNER.
2259.1
[88.94]
571.7
[22.51]
CL
24.8
FRONT OF VEHICLE 101.8 [.98]
1628 10
[64.09] [4.01]
60.4 [.39]
[2.38] 52
[2.04]
7 3
812.9 [.12]
[32]
FRONT OF VEHICLE
ITEM #3 IS WELDED TO ITEM #1
23.1
ON ALL 4 EDGES. [.91]
86 13
1 WELD SHEET METAL [.51] 177.5
[3.39] RELIEF AFTER FORMING
CL 14 [6.99]
106
[.55] DIA 4 HOLES [4.2] 12
SUPPORT BODY ISOLATOR TO CROS S GUSSET CROSS SILL TO
44 [.47]
SILL L.H. SHOWN. R.H. SYMETRICALLY OUTER SUPPORT R.H. SHOWN.
[1.75] OPPOSITE. L.H. SYMETRICALLY OPPOSITE.
IVM176MID2

FIGURE P6 - E-SERIES SCHOOL BUS CNG FUEL SYSTEM AND FLOOR STRUCTURE -
176 INCH WHEELBASE

E-SERIES (May, 2003) 51 STATEMENTS OF CONFORMITY

 ITEM PART NAME MATERIAL QUANTITY
1 SUPPORT RAIL R.H. 6.35mm [0.25] HRLC STEEL 1
2 SUPPORTRAIL L.H. 6.35mm [0.25] HRLC STEEL 1
3 RISER BRACKET 6.35mm [0.25] HRLC STEEL 6
4 FRONT CROSS 1.9mm [0.075] HRLC STEEL 3
5 MIDDLE CROSS 1.9mm [0.075] HRLC STEEL 2
6 GUSSET L.H. 1.9mm [0.075] HRLC STEEL 5
7 GUSSET R.H. 1.9mm [0.075] HRLC STEEL 5
8 OUTER SUPPORT 3.0mm [0.120] HRLC STEEL 2
9 FLOOR (NOT SHOWN) 1.9mm [0.075] HRLC STEEL 1

BLIND RIVET FASTENERS

The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength
of 3600 lb and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATION

Items 4 to Items 9 48 Estimated 101.6mm [4.00] centers on frt and rr flange –
50.8mm [2.00] stagger frt and rr flange
Items 4 or 5 to Items 6 or 7 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
Items 6 or 7 to Items 8 3 on vertical side of item 8, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers

1470 952.1 526.3 2375.0

[57.9] [37.5] [20.7]
[93.5] MINIMUM
6

5 4
4 6 FORD PROVIDED
M12 BOLT (8 REQ’D)
7 TORQUE 70Nm 52 ft lb
6
8

3
2

7
7 7
1 3 7

FORD PROVIDED
ISOLATORS (6)

IVM158MID

FIGURE P7 - E-SERIES CNG SCHOOL BUS MIDSHIP FUEL SYSTEM AND FLOOR STRUCTURE -
158 INCH WHEELBASE

STATEMENTS OF CONFORMITY 52 E-SERIES (May, 2003)

 BOTH ENDS OF ITEMS #4 AND #5 CROSS SILLS MUST BE
WELDED COMPLETELY TO ITEM #8 LEFTSIDE AND ITEM #11
RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDS
THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN
COMPLETED.

172
C
[6.77] 691.7 2369
141.3 [27.23] [93.27]
985.6
[5.56] [38.8]

39.2
68.4 [1.54] 4 PLACES
[2.69]
36.1 4
[1.42]
67 TYP
[2.64] O
45 2 PLACES
14
[.55] DIA
43.8
5 [1.72]
2 PLACES

10
[.39]
134 2 PLACES
O [5.28]
45 2 PLACES TYP
2369
[93.27] 43.8 110
[1.72] [4.33]
2 PLACES 30.7
42.7 42.2
[1.68] [1.27]
CL [1.66]
10
[.39] CL
3
2 PLACES
134
[5.28] SEE VIEW C FOR
HOLE DIMENSIONS
41.7 LOCATIONS
[1.64]
128.3 67
FRONT OF VEHICLE [5.05] [2.64] M12 BOLT & NUT GC 10.9
65.4 (24 REQ’D)
[2.57]
2 PLACES 13 TORQUE 70 Nm 52 ft. lb.
170 [.51] DIA
[6.69] 4 HOLES

985.6 TO CL OF 36.0 DIA HOLE

[38.8]

36 36.0 DIA 2 HOLES

[1.42] 1470
[50.87]
13 DIA 8 HOLES
[.51]
42.7
[1.68]
200
[7.87]

46.8
[1.84]
134 TYP 21.4 8
[5.28] 86 [.84]
3.39
67 TYP
[2.64]
FRONT OF VEHICLE SUPPORT CROSS SILL OUTER L.H. SHOWN .
FRONT OF VEHICLE
R.H. SYMETRICALLY OPPOSITE.
VIEW C
TRIM WITH 45 ANGLE
TO REMOVE SHARP CORNER.

571.7
[22.51]
1887.9 1801.9
[74.33] [70.94] 24.8
CL [.98]
FRONT OF VEHICLE
101.8 10
[4.01] [.39]
989 52
60.4 [2.04]
[38.94] [2.38]
7 3
503.9 [.12]
[19.84]
ITEM #3 IS WELDED TO ITEM #1 FRONT OF VEHICLE
ON ALL 4 EDGES. 23.1
86 [.91]
[3.39] 1 13
WELD SHEET METAL [.51] 177.5
CL RELIEF AFTER FORMING [6.99]
14 106
[.55] DIA 4 HOLES SUPPORT BODY ISOLATOR TO CROS S [4.2] 12
44 GUSSET CROSS SILL TO [.47]
[1.75] SILL L.H. SHOWN. R.H. SYMETRICALLY OUTER SUPPORT R.H. SHOWN.
OPPOSITE. L.H. SYMETRICALLY OPPOSITE.
IVM158MID2

FIGURE P8 - E-SERIES CNG SCHOOL BUS MIDSHIP FLOOR STRUCTURE - 158 INCH WHEELBASE

E-SERIES (May, 2003) 53 STATEMENTS OF CONFORMITY

303 U.S. Requirements: 1106 Canadian Requirements:
The statement below Is applicable to all incomplete The statements below are applicable to the following
vehicle types if the GVWR Is 4536 kg [10,000 lb] or incomplete vehicle types with GVW ratings of 4536
less: kg [10,000 lb] or less:
Conformity with Standard 303, Fuel System Integrity • Chassis Cab
of Compressed Natural Gas Vehicles, is not • Incomplete E-Series Van or Wagon
substantially affected by the design of this incomplete • Cutaway
vehicle; accordingly Ford Motor Company makes no
representation as to conformity with this Standard. These vehicles, when completed, will conform to
Standard 1106, Noise Emissions, Section 2, if noise
303 U.S. Requirements: control devices or elements of design are not modified
The statements below are applicable to the E-450 removed or rendered inoperative. Examples of such
Cutaway when equipped with the Compressed Natural devices or elements of design are:
Gas (CNG) package and School Bus Prep Package, • Fender apron absorbers, fender apron barriers,
and is completed as a school bus: underbody noise shields and acoustic absorption
This vehicle when completed will conform to Standard material.
303, Fuel System Integrity if: • Engine speed governor or electronic control intended
• The following fuel components as installed by Ford to control maximum engine speed.
Motor Company are not removed, altered, or modified • Engine air duct, air intake choke or silencer, air
in any way except as specified in the following cleaner and air cleaner element.
representations: • Exhaust system components including the catalyst
– Fuel tank and attachment hardware, including inlet pipe, muffler, outlet pipe, resonator and diffuser.
sender unit, and fuel tank shield • Engine cooling fan and cooling fan clutch.
– Fuel filler valves, pipes, hoses, and attaching
1106 Canadian Requirements:
hardware
– Fuel shut-off switch (Inertia switch) The statements below are applicable to the following
incomplete vehicle types with GVW ratings of more
• The completed vehicle when loaded to the than 4536 kg [10,000 lb]:
requirements of S7.1.6 (c) does not exceed the
• Chassis Cab
GVWR or GAWR’s.
• Incomplete E-Series Van or Wagon
• The floor structure of the Second Unit Body and
rear bumper are manufactured and installed to the • Cutaway
specifications found in Figures P3-P8 on pages These vehicles, when completed, will conform to
48-53. Standard 1106, Noise Emissions, Section 4, if noise
• The fill hoses, hose clamps, and fuel sender unit must control devices or elements of design are not modified
be installed to the specification on Figure K, page 44 removed or rendered inoperative. Examples of such
(which has been drawn for a gasoline fuel system, but devices or elements of design are:
the filler location for natural gas is noted). • Fender apron absorbers, fender apron barriers,
• No other alteration or modification made to the underbody noise shields and acoustic absorption
incomplete vehicle as manufactured by Ford Motor material.
Company and no other components or structure • Engine speed governor or electronic control intended
installed by a subsequent stage manufacturer result to control maximum engine speed.
in penetration, separation, or other damage to the • Engine air duct, air intake choke or silencer, air
fuel system or any portion thereof when the vehicle cleaner and air cleaner element.
is tested in any manner specified by applicable
• Exhaust system components including the catalyst
provisions of Standard 303.†
inlet pipe, muffler, outlet pipe, resonator and diffuser.
304 U.S. Requirements: • Engine cooling fan and cooling fan clutch.
The statement below is applicable to all incomplete
vehicle types:
All compressed natural gas tanks supplied by Ford
Motor Company are in full conformity with Standard 304,
Compressed Natural Gas Fuel Container.
For tanks not supplied by Ford Motor Company,
conformity is not substantially affected by the design
of this incomplete vehicle; accordingly, Ford makes no
representation as to conformity with this Standard.

† 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 303.

STATEMENTS OF CONFORMITY 54 E-SERIES (May, 2003)

 CANADIAN VEHICLES
(Vehicles to be completed for sale or use in Canada)

VEHICLE IDENTIFICATION • Electrical grounds on all components must be retained.

Refer to the Vehicle Description section of this manual • Metallic components installed on the body or chassis must
on page 5, for additional information. Incomplete vehicles be grounded to the chassis.
produced by Ford Motor Company require, for certain • Electrical circuits added to the vehicle must not be installed
applications, optional Prep Packages or trim codes which are near the high voltage ignition components.
listed on the Completed Vehicle Types charts on page 6.
• Only “static conductive” accessory drive belts should be
DAYTIME RUNNING LAMP (DRL) used. Fan, water pump, power steering, and other belts
should be of the OEM type or equivalent that will not build
Compliance representations for CMVSS 108, Lighting and up a static electrical charge.
CMVSS 108.1, Headlamps, are on page 19. The following
items are also required for CMVSS 108 and 108.1 • Engine compartment wiring must not be rerouted in any
compliance: manner.
• The DRL module circuits are not to be altered. • The Powertrain Control Module (PCM) must not be relocated
from the position as installed by Ford Motor Company.
• DRL module is not to be repositioned.
• The E-Series Basic (Stripped) Chassis is not to be equipped
with more than two headlamps when equipped with a DRL
module as provided by Ford Motor Company.

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-M92”. 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 has no control
over how this incomplete vehicle is completed by subsequent
stage manufacturers, Ford 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
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 coil, ground straps, ignition component
shields, accessory drive belts, instrument voltage regulator
suppressor assembly, and ignition coil suppressor assembly.
More specifically:
• All components required to suppress RFI emissions, which
are removed during service, repair, or completion of the
vehicle, must be reinstalled in the manner in which they
were installed by Ford.
• Shields on ignition coil must remain installed.
• Replacement spark plugs, ignition wires, and ignition coil
must be equivalent in their RFI suppression properties to
original equipment.

E-SERIES (May, 2003) 55 CANADIAN VEHICLES

 EMISSION CERTIFICATION INFORMATION
CAUTION: IMPORTANT:
U.S.: It is the responsibility of the body builder, installer, or
2004 MODEL YEAR VEHICLES ARE EMISSION subsequent stage manufacturer to ensure that the maximum
CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS completed vehicle curb weight and frontal area specified by
OF THE UNITED STATES. FOR EXAMPLE, VEHICLES Ford are not exceeded. If these restrictions are exceeded,
CERTIFIED AND LABELED FOR SALE IN CALIFORNIA or if the vehicle is modified such that it will not comply with
CAN NOT BE SOLD IN THE STATES THAT REQUIRE applicable emission standards throughout its useful
FEDERALLY CERTIFIED VEHICLES AND VEHICLES life, the body builder, installer, or subsequent stage
CERTIFIED TO FEDERAL STANDARDS CAN NOT manufacturer will be considered a manufacturer for purposes
BE SOLD IN STATES THAT REQUIRE CALIFORNIA of complying with U.S. Federal, California, or Canadian
CERTIFIED VEHICLES. IT IS THE SUBSEQUENT STAGE exhaust and evaporative emission requirements, and
MANUFACTURER’S RESPONSIBILITY TO PURCHASE Federal fuel economy standards, labeling, and certain
A VEHICLE CERTIFIED FOR THE STATE/AREA IN WHICH other requirements.
THE VEHICLE WILL BE SOLD. EPA HAS STATED THAT compliance with applicable federal or California emission
UNDER CERTAIN CIRCUMSTANCES THEY WILL NOT standards. Refer to guidance under "Emission Control
ENFORCE THESE REQUIREMENTS. FOR FURTHER Modifications" in the Ford "Body Builders Layout Book". The
GUIDANCE CONSULT EPA’S “POLICY ON CROSS 5.4L, 6.0L Diesel and 6.8L engines used in Strip Chassis,
BORDER SALES OF CALIFORNIA VEHICLES.” Cutaways, and Chassis Cabs (incomplete vehicles) are
CANADA: certified to heavy-duty engine (>3856 kg or 8500 lb) protocol
IF THE COMPLETED VEHICLE IS INTENDED FOR SALE and therefore are not limited by weight and frontal area
OR USE IN CANADA, THE INTERMEDIATE OR FINAL restrictions in terms of emissions certification. To determine if
STAGE MANUFACTURER MUST INSURE THAT THE your vehicle is certified to light-duty or MDV protocol, refer to
INCOMPLETE VEHICLE IS ORDERED THROUGH A the Emissions Control Information decal which is located in
CANADIAN DEALER OR IS ORDERED FROM FORD the engine compartment.
MOTOR COMPANY WITH THE APPROPRIATE CANADIAN Incomplete vehicles using engines which are certified as
MARKET OPTION CODE. FAILURE TO DO SO MAY heavy duty engines will not have frontal area or curb weight
RESULT IN AN INCOMPLETE VEHICLE THAT IS BUILT restrictions based on exhaust emissions regulations. It is
WITH AN EMISISONS SYSTEM AND LABELING THAT ARE important, however, that the final stage manufacturer observe
NOT IN COMPLIANCE WITH THE REQUIREMENTS OF vehicle restrictions from vehicle safety requirements, etc.,
THE CANADIAN ENVIRONMENTAL PROTECTION ACT. which are located elsewhere in this manual. Additional
emissions certification information is contained in the Ford
EXHAUST EMISSIONS AND FUEL ECONOMY Truck Body Builders’ Layout Book for the model year and type
Most incomplete vehicle(s) offered by the Ford Motor Company of this incomplete vehicle.
for 2004 model year will be in the >3856 kg [8,500 lb] HIGH ALTITUDE REQUIREMENTS
classification. Generally, the medium/heavy duty engines used
in these vehicles will be certified to Federal, Canadian, or United States Environmental Protection Agency regulations
California exhaust and evaporative emissions requirements for the 2004 model year do not contain unique emission
for medium/heavy duty engines. certification requirements for trucks that will be sold or
delivered to customers for principal use above 1,219 m
MEDIUM DUTY PASSENGER VEHICLES (MDPV) [4,000 ft.].
EPA has adopted separate emissions standards and EMISSION CONTROL HARDWARE
requirements for MDPVs beginning in 2004. A MDPV is
defined as a heavy-duty vehicle with a GVWR under 10,000 Any body builder, installer, or subsequent stage manufacturer
lbs. designed primarily for the transportation of persons (with must also assure that all emission control hardware furnished
seating for up to 12 persons, or up to 9 persons rearward with incomplete vehicles is on the vehicle and is operational
of the drivers seat). E-Series vehicles ordered with the and that applicable instructions for incorporating such
RV-Prep package are certified to MDPV standards and may hardware into the completed vehicle’s electrical or mechanical
be converted to MDPVs without requiring additional emission systems are strictly followed.
certification. Further, to avoid any question of certification coverage,
FRONTAL AREA AND WEIGHT RESTRICTIONS: approval of any modification or use of an engine or vehicle
which may render inoperative any of the emission control
All 4.6L and some 5.4L E-Series Vans and Wagons are components must be obtained from the United States
certified to complete light duty <3856 kg [8500 lb] protocol and Environmental Protection Agency by the manufacturer making
require vehicle weight and frontal area restrictions. Complete such modification or use prior to distribution, sale, offering for
5.4L and 6.8L Vans and Wagons certified to California >3856 sale, introduction, or delivery for introduction of the subject
kg [8500 lb] Medium Duty Vehicle (MDV) protocol also have vehicle into U.S. commerce. Additionally, the manufacturer
vehicle weight and frontal area restrictions. Modifiers that making such modification or use must obtain approval from
add weight to a vehicle or increase the frontal area of a light- the California Air Resources Board if the new vehicle will be
duty/MDV vehicle prior to sale and delivery to the ultimate delivered for sale or use in the State of California.
purchaser, may be required to re-certify the vehicle for

IMPORTANT:
For purposes of Government Regulation, a body builder,
installer, or any subsequent manufacturer may be considered
a manufacturer.

EMISSION CERTIFICATION INFORMATION 56 E-SERIES (May, 2003)

UNLEADED GASOLINE LABEL WARRANTY AND MAINTENANCE
Regulations no longer require the manufacturer to affix A copy of the appropriate Ford Truck Owners Guide and
permanent labels reading “Unleaded Gasoline Only” or Warranty Facts Booklet must be installed in every vehicle
“Unleaded Fuel Only” to vehicles destined for sale in the United prior to sale to the ultimate purchaser in order to provide
States or Canada. Such labels may however be required for emission systems warranty information and maintenance
vehicles sold into other markets. It is the responsibility of schedules. It also provides, where required by EPA noise
the body builder, installer, or any subsequent manufacturer control regulations for vehicles having GVWR over 4536 kg
to properly label vehicles for the market in which they are [10,000 lb], noise emissions warranty information, instructions
sold. for maintenance, use, and repair of vehicle noise emission
EXTERIOR NOISE control systems, a maintenance record format, and list of
prohibited tampering acts.
New vehicles which have a gross vehicle weight rating in
excess of 4536 kg [10,000 lb], include a partially or wholly EVAPORATIVE EMISSIONS
enclosed operator’s compartment, and are manufactured for All 2004 Federal light and heavy duty trucks and all California
use in the United States, must comply with U.S. Environmental vehicles with gasoline engines are required to comply
Protection Agency’s exterior noise emission regulations for with evaporative emissions requirements established by
medium and heavy trucks (40 CFR Part 205, Subpart B) which the Environmental Protection Agency or the California Air
establish a noise emission limit of 80 dB (A). Resources Board. Production fuel systems supplied on
However, the Basic (Stripped) Chassis as built by Ford is too incomplete 2004 model year trucks manufactured by Ford
incomplete to constitute a regulated vehicle and Ford does Motor Company comply with these requirements. If the
not represent that it complies with those regulations. With subsequent stage manufacturer adds to or modifies the
respect to the Basic (Stripped) Chassis, it is the responsibility fuel system in any manner, it becomes the responsibility
of the subsequent stage manufacturer of that vehicle at the of the modifier to assure compliance with the applicable
time it first conforms to the regulatory definition of “vehicle” to regulations. Refer to the Design Recommendation section of
comply with the requirements imposed upon manufacturers the Ford Truck Body Builders’ Layout Book, for additional Fuel
by these regulations. System Evaporative Emissions information.

TAMPERING WITH NOISE CONTROLS MALFUNCTION INDICATOR LIGHT (MIL)

Federal law prohibits the removal or rendering inoperative by The “Malfunction Indicator Light” is used to indicate
any person, other than for purposes of maintenance, repair, or malfunctions of the Electronic Engine Control System and
replacement, of any device or element of design incorporated certain emissions-related components. For all incomplete
into such vehicle for the purpose of noise control prior to its vehicles, except Basic (Stripped) Chassis (which is not
sale or delivery to the ultimate purchaser or while it is in use. equipped with an instrument panel), it is Ford installed and
Federal Law also prohibits the use of such vehicle after such operational.
device or element of design has been removed or rendered The E-Series Basic (Stripped) Chassis vehicles, has the
inoperative by any person. warning light installed in the instrument cluster, which is
Among those acts presumed to constitute tampering are the shipped in the dunnage box. If an alternate instrument
acts listed below: cluster is utilized, the final stage manufacturer must install an
operational light in the instrument cluster. This light must glow
• Removal of fender apron absorbers, fender apron amber and display the message “Malfunction Indicator Light
barriers, underbody noise shields, or acoustical (MIL)”. It should be recognized that this light is a requirement
absorptive material. of emission certification.
• Removal of or rendering inoperative the engine speed
governor so as to allow engine speed to exceed
manufacturer’s specifications.
• Removal or modification of air duct, air intake choke or
silencer, air cleaner, or air cleaner element.
• 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.

E-SERIES (May, 2003) 57 EMISSION CERTIFICATION INFORMATION

OZONE DEPLETING SUBSTANCE (ODS) CALIFORNIA MOTOR VEHICLE EMISSION CONTROL
The Clean Air Act of 1990, Section 611 requires any product LABEL
(i.e., completed vehicle) containing or manufactured with To meet California emission certification regulations, the
any Class I Ozone Depleting Substance on, or after May Emission Control Information (tune-up) label must be welded,
15,1993 must be identified with a “clearly and conspicuously riveted, or otherwise permanently attached to an area within
attached label.” the engine compartment or to the engine in such a way that it
Ford Motor Company has eliminated Class I ODS from its will be readily visible to the average person after installation
manufacturing processes. All 2004 Ford Truck incomplete of the engine in a vehicle. In selecting an acceptable location,
vehicles will not have Class I ODS content. the manufacturer shall consider the possibility of accidental
damage (e.g., possibility of tools or sharp instruments coming
Manufacturers, including subsequent stage manufacturers, in contact with the label). The label shall be affixed in such a
are required to label their products if the product, including manner that it cannot be removed without being destroyed or
any component (whether manufactured by that manufacturer defaced, and shall not be affixed to any part which is likely to
or not), contains a Class I ODS or if the manufacturer used a be replaced during the vehicle’s useful life. For motor vehicles
Class I ODS in the manufacturing of the product. In the rated at 6350 kg [14,000 lb] GVWR or less, the label shall not
case where Ford provides a label saying the incomplete be affixed to any equipment which is easily detached from the
vehicle contains a Class I ODS that information must be vehicle. As used in these specifications, readily visible to the
placed on the product warning label. (See EPA regulation on average person shall mean that the label shall be readable
wording, placement, size, and combining labels.) In Canada from a distance of 460 mm [18 in] without any obstructions
consult the appropriate Provincial or Territorial Ministry of from vehicle or engine parts (including all manufacturer
Environment. 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
EMISSION CONTROL INFORMATION LABEL no smaller than 8 point type size provided that no vehicle or
To meet United States Environmental Protection Agency engine parts (including all manufacturer available optional
regulations, the Important Vehicle Information (tune-up and equipment), except for flexible parts that can be moved out of
fuel tank capacity) labels must be affixed in a location that is the way without disconnection, obstruct the label.
readily visible after installation and in such a manner that it Completed vehicles for retail sale in California require a
cannot be removed without destroying or defacing the label. machine-readable vehicle identification number (VIN) bar-
The label shall not be affixed to any equipment that is easily code label made of paper, plastic, metal, or other permanent
detached from the vehicle. material which shall be affixed in a readily visible location to
When emission control labels are supplied but not attached either the door-latch post next to the driver’s seating position,
to the vehicle (i.e., tune-up label or fuel tank label), they must the door edge that meets this door-latch post, or above the
be permanently mounted in a readily visible location to meet instrument panel in a location clearly visible through the lower
the preceding requirements. In addition, whether the label left corner of the windshield.
is already affixed or to be affixed, no components shall be • All incomplete vehicles except Basic (Stripped) Chassis
installed which visibly obscure the label in any way that type vehicles will conform to this standard.
fails to satisfy the visibility requirements described in the
California Emission Control Label Specifications. For Canadian • Basic (Stripped) Chassis type vehicles:
requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii), Conformity with CARB Motor Vehicle Emission Control
as applicable. 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
CALIFORNIA FUEL VAPOR RECOVERY with this requirement.
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 For the VEC† and VIN labels, sufficient clearance shall be
pipes installed per the figure on page 44 will comply with the provided to use a non-contact bar-code Reading Wand. For
“Specifications For Fill Pipes and Openings of Motor Vehicle the tune-up label and vacuum hose routing diagram label, the
Fuel Tanks” referenced in Title 13 California Administrative label and any adhesives used shall be designed to withstand
Code provided no part of the aftermarket body, as installed, typical vehicle environment conditions in the area where the
intrudes within a 254mm [10 in] radius cylinder which has its label is attached for the vehicle’s total expected life. Typical
axis parallel to the ground at point “Z” (Figure K on page 44 vehicle environmental conditions shall include, but are not
illustrates a typical point Z). The cylindrical zone uses the axis limited to, exposure to engine lubricants and coolants (e.g.,
described above, starts at the outer most surface of the Ford gasoline, motor oil, brake fluids, water, ethylene glycol),
supplied fuel filler housing, and projects outward (away from under hood temperatures, steam cleaning, and paints or
the frame). The fuel pipe housing component is shown on the paint solvents.
referenced figures and is attached to the aftermarket body via
3/16 inch diameter rivets.

† Vehicle Emission Control

EMISSION CERTIFICATION INFORMATION 58 E-SERIES (May, 2003)

RADIO FREQUENCY INTERFERENCE (RFI) Devices that emit radio frequency (RF) energy such as AM/FM
The ignition system on your vehicle (if other than a Basic radios, mobile telecommunications systems (two-way radios,
(Stripped) Chassis) has been designed to be capable of telephones), and radio controlled security systems are subject
compliance with RFI requirements established by the Canadian to the rules and regulations of the Federal Communications
government. However, because Ford has no control over Communication (FCC), including 47 CFR Parts 2 and 15. Any
how an incomplete vehicle is completed by subsequent stage such system installed in a vehicle should comply with those
manufacturers, Ford does not represent that the completed rules and should be installed only by a qualified technician.
vehicle incorporating the Ford-built components will comply In addition, to ensure continued compliance with the FCC’s
with those requirements. Any ignition system component regulations, RF devices must not be modified or changed in
(i.e.: spark plugs, ignition wiring, coil suppressor assembly, a manner not expressly approved by Ford Motor Company
etc.) that is replaced should be replaced by the same Ford Mobile Communication Systems. RF devices particularly, if
Motor company part number or equivalent to maintain RFI not properly installed, may adversely affect the operation of
suppression. the vehicle. For example, such systems when operated may
cause the engine to stumble or stall. In addition, such systems
While there are currently no RFI regulations in the United themselves may be damaged or their operation affected by
States specifically applicable to automotive ignition systems, the operation of the vehicle. (Citizens Band [CB] transceivers,
all Ford Light Trucks are built with ignition system components garage door openers, and other transmitters whose power
the same or equivalent to those supplied on Canadian output is 5 watts or less, ordinarily will NOT affect vehicle
vehicles. operation.)
Ford Motor Company recommends that all ignition system Because Ford has no control over the operation or manufacture
service be performed at a Ford authorized service facility to of such systems or their installation, Ford cannot assume
help hold RFI emissions levels to a minimum. responsibility for any adverse effects or damage if this
Additional RFI information is contained on page 55 of this equipment is used.
manual.

E-SERIES (May, 2003) 59 EMISSION CERTIFICATION INFORMATION

SUPPLEMENTS

60 E-SERIES (May, 2003)

 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. To obtain a free copy of this publication on CD-ROM or to
receive an order form for additional CD-ROM’s or books please visit our website at
www.fleet.ford.com/truckbbas/. Under Publications select Body Builders Order Forms.
All dealer requests can be handled online. All other U.S. orders should be faxed 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 publications are a few of many manuals which are available from Helm
Incorporated; call: 1-800-782-4356
• Ford Truck Shop Manuals
• Ford Towing Manual
• Ford Electrical & Vacuum Trouble Shooting Manual
• Ford Wiring Diagram

FORD TRUCK BODY BUILDER ADVISORY SERVICE

The Ford Truck Body Builder Advisory Service may be consulted regarding informa-
tion contained in this manual. Call 1-877-840-4338 or e-mail [email protected] for
assistance or Fax inquiries to (313) 594-2633 accompanied with a cover sheet indicat-
ing “Attention to: Ford Truck Body Builder Advisory Service,” along with your name,
address and telephone number.

E-SERIES (May, 2003) REFERENCE INFORMATION

 FORD MOTOR COMPANY
THE AMERICAN ROAD
DEARBORN, MI 48121

FORD MOTOR COMPANY OF CANADA LIMITED

THE CANADIAN ROAD
OAKVILLE, ONTARIO L6J 5E4