1 General Information
1.1 About This Manual........................ 6
1.1.1 Introduction........................................... 6
1.1.2 Important Safety Instructions............. 6
1.1.3 Warnings, Cautions and Notes in This
Manual.................................................... 6
1.1.4 How to Use This Manual..................... 6
1.2 Commercial and Legal Aspects...
7
1.2.1 Terminology........................................... 7
1.2.2 Warranty on Ford Vehicles.................. 7
1.2.3 Legal and Vehicle Type Approval....
7
1.2.4 Alternative Type Approval.................... 7
1.2.5 Legal Obligations and Liabilities.......... 7
1.2.6 General Product Safety
Requirement.......................................... 7
1.2.7 Product Liability..................................... 8
1.2.8 Restraints System................................ 8
1.2.9 Drilling and Welding.............................. 8
1.2.10 Minimum Requirements for Brake
system and Load Apportioning Valves
................................................................. 8
1.2.11 Road Safety........................................... 8
1.3 Contact Information..................... 9
1.4 Conversion Type......................... 14
1.5 Conversion Homologation......... 23
1.6 Electromagnetic Compatibility
(EMC).......................................... 24
1.6.1 Antenna Location............................... 24
1.7 Vehicle Duty Cycle Guidelines.... 25
1.7.1 Conversion Affect on Fuel Economy
and Performance............................... 25
1.7.2 Vehicle Ride and Handling
Attributes............................................. 25
1.8 End of Life Vehicle (ELV)
Directive..................................... 26
1.9 Jacking....................................... 27
1.10 Lifting.......................................... 29
1.11 Noise, Vibration and Harshness
(NVH)........................................... 31
1.12 Vehicle Transportation Aids and
Vehicle Storage.......................... 32
1.13 Package and Ergonomics.......... 33
1.13.1 General Component Package
Guidelines............................................ 33
1.13.2 Driver Reach Zones........................... 33
1.13.3 Driver Field of View............................. 33
1.13.4 Conversion Affects on Parking Aids..
33
1.13.5 Aids for Vehicle Entry and Exit.......... 33
1.14 Package and
Ergonomics—Specifications...... 34
1.14.1 Recommended Main Dimensions....
34
1.14.2 Recommended Nominal Body
Lengths for Chassis Cab models....
36
1.14.3 Front, Rear and Side Under-run
Protection............................................ 38
1.14.4 Recommended Main Load Area
Dimensions for Bulkhead with
Depression Driver Side...................... 39
1.14.5 Recommended Main Load Area
Dimensions for Bulkhead with Full
Depression.......................................... 40
1.14.6 Recommended Main Load Area
Dimensions for Double Cab In Van
Bulkhead.............................................. 41
1.15 Hardware—Specifications.......... 43
1.16 Load Distribution—Specifications.
44
1.16.1 Load Distribution Calculations - Driver
and Passenger Weight Distribution...
44
1.16.2 Center of Gravity ............................... 46
1.17 Towing........................................ 54
1.17.1 Towing Requirements....................... 54
1.17.2 Towing.................................................. 54
2 Chassis
2.1 Suspension System.................... 57
2.2 Front Suspension....................... 58
2.2.1 Springs and Spring Mounting........... 58
2.3 Rear Suspension........................ 59
2.3.1 Springs and Spring Mounting........... 59
2.3.2 Rear Anti-Roll Bar............................... 59
2.4 Wheels and Tires........................ 60
2.4.1 Wheel Clearance................................ 60
2.4.2 Tire Manufacturers............................. 60
2.4.3 Spare wheel........................................ 60
2.4.4 Painting Road Wheels....................... 60
2.5 Driveshaft.................................... 61
2.5.1 Power Take Off.................................... 61
2.6 Brake System............................. 62
2.6.1 General................................................ 62
2.6.2 Kerb Mass Data.................................. 62
2.6.3 Brake Hoses General........................ 62
2.7 Parking Brake............................. 63
2.7.1 Relocated Parking Brake Lever....... 63
2.8 Hydraulic Brake Actuation......... 64
2.8.1 Load Apportioning Valves................. 64
2.8.2 Front and Rear Brakes...................... 64
2.9 Anti-Lock Control - Stability
Assist.......................................... 65
3 Powertrain
3.1 Engine......................................... 66
3.1.1 Engine Power Curves....................... 66
3.2 Engine Cooling............................ 75
3.2.1 Auxiliary Heater Systems.................. 75
3.2.2 Auxiliary Heater Installation............... 76
3.2.3 Air Flow Restrictions........................... 76
3.3 Accessory Drive......................... 77
3.3.1 Front End Accessory Drive 2.4l Diesel
and 2.3l Petrol..................................... 77
3.3.2 Front End Accessory Drive 2.2l
Diesel.................................................... 79
3.4 Electronic Engine Controls......... 81
3.5 Clutch......................................... 82
3.6 Manual Transmission................. 83
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