Conversion Van – Qualified Vehicle Modifier Unique Guidelines and Requirements Van Conversion

Van Conversion
Conversion Van – Qualified Vehicle Modifier
Unique Guidelines and Requirements
The following section of the Guidebook describes guidelines and requirements that are unique to the Conversion
Van – Qualified Vehicle Modifier (CV– QVM) program. These items are in addition to those in the main or
common items portion of the Guidebook. In order to receive a fully meets ("FM") rating, a builder must receive a
"YES" on all minimum requirements ("double-boxed") items in both sections of the book as well as score a
minimum of 85% on the Other Criteria ("OC") items in the book.
Copies of this guidebook can be obtained by calling Program Headquarters at (800) 245-7343. Answers to
engineering questions regarding its content can be obtained by contacting the:
FORD TRUCK BODY BUILDERS ADVISORY SERVICE: 1-877-840-4338 or bbasqa@ford.com
TABLE OF CONTENTS
A. DESIGN AND MANUFACTURING GUIDELINES
C-D0700 Customer Support ..........................................................................................................................................2
C-E0100 Heat Management ...........................................................................................................................................2
C-E0200 Climate Control ...............................................................................................................................................2
C-E0300 Wheels and Tires ............................................................................................................................................3
C-E0400 Steering and Suspension ..............................................................................................................................3
C-E0600 Powertrain---Engine/Transmission/Axle.......................................................................................................3
C-E0700 Fuel System .................................................................................................................................................... 4
C-E0800 Exhaust System ..............................................................................................................................................4
C-E0900 Frame
.....................................................................................................................................................4
C-E1000 Body and Seating............................................................................................................................................5
C-E1100 Electrical
.....................................................................................................................................................6
C-E1200 Materials, General ...........................................................................................................................................7
B. UNIQUE INDUSTRY MODIFICATIONS
C-F0100 Design & Manufacturing Guidelines………………………………………………………………… 8
C-F0200 Functional Items……………………………………………………………………………………………………… 8
C-F0300 Fit and Appearance Items…….…………………………………………………………………………………….. 9
Originator: MVE
QVM Guide (Conversion Van Unique)
1
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
C-D0700
CUSTOMER SUPPORT
As a final-stage manufacturer building Ford-based conversion vans, you are expected to share in
Ford’s commitment to respond to the needs of the customer. This section of the guide presents a
number of recommendations, which will assist you in achieving customer support objectives.
C-D0701
A warranty analysis system should be used to identify trends in recurring quality concerns. Trends
should be documented. Production changes, which would resolve each of these concerns, should
then be documented. Warranty analysis should be broken down according to chassis manufacturer in
order to further track warranty trends.
Conversion package content can be complex. Customers have a need to be provided with information
clearly describing the product including electrical information, service procedures, available cargo
weight data, accessory operational information, and warranty coverage.
C-D0702
Information on additions and alterations made to the Ford factory electrical system, as well as all
wiring and devices added by the converter should be provided as owner information—including
electrical sketches. Fuses should be located in an accessible area and service information should be
provided to the customer.
C-E0100
HEAT MANAGEMENT
C-E0101
Do not remove, reposition, or otherwise modify any existing OEM body, chassis, or exhaust heat
shielding.
•
•
All added heat shields should provide a minimum clearance of ¾ inch to all moving components.
Added heat shields should be fabricated and attached in such a manor as to minimize the
possibility of rattles and "oil-canning".
C-E0200
CLIMATE CONTROL – HEATER AND AIRCONDITIONING
C-E0201
AIR CONDITIONING COMPRESSOR
AUXILIARY AIR CONDITIONING and HEATER SYSTEM
C-E0202
E-Series vans equipped with the RV Prep Package include Ford factory installed in-dash A/C controls,
and are available with the Auxiliary Heater and A/C Connector Package (an Auxiliary Heater
Connector Package is also available). To avoid potential A/C compressor damage or refrigerant loss in
the A/C system, certain precautions should be taken (refer to CVQP Quality Bulletin C-4).
C-E0203
Installing an auxiliary A/C system on units which are not equipped with the Auxiliary Heater and A/C
Connector Package is not recommended. If, however, you choose to do this, these recommendations
should be followed:
• The aftermarket auxiliary A/C system shall be coupled directly to the factory in-dash A/C system.
These couplings should be made at production connection points and include fittings which are
compatible with Ford production components.
•
Additional compressor oil may be needed to maintain a level of 4% oil in the total system.
Typically, most units will take 3-4 ounces of additional oil, however, exact amounts should be
calculated based on the volume of refrigerant being added.
Compressor lubricating oil should not be added to vehicles equipped with the Auxiliary Heater and
A/C Connector Package.
• After auxiliary A/C and/or Heater installation is complete, all connections should be inspected to
ensure that system is free of leaks.
• Routing should be inspected to ensure that it is free of kinked or pinched lines.
Originator: MVE
QVM Guide (Conversion Van Unique)
2
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
•
The routing of the vacuum line should be such that it is protected from abrasion, pinching or
kinking. Vacuum line should be protected by grommets through metal holes.
Auxiliary A/C-Heater air ducts should not be pinched, flattened, or kinked during assembly of the
vehicle (it may be necessary to alter the sequence in which ducts are installed to ensure that they
are not damaged during build of the unit).
C-E0203
Cont’
•
C-E0300
WHEELS AND TIRES
C-E0301
When considering any alteration to tire and wheel systems, you should refer to the Incomplete Vehicle
Manual to determine specific requirements for FMVSS compliance.
If it is deemed necessary to install aftermarket wheels and tires, carefully check tires for proper
balance and inflation, and retain all wheel/tire information on file.
If non-OEM wheel offset (center of rim to mounting face of wheel) differs from the OEM wheel, some
characteristics such as vehicle handling, brake cooling, and wheelhouse clearance may be affected
and axle degradation may occur.
C-E0302
C-E0400
STEERING AND SUSPENSION
C-E0401
Dynamic crash situations should be considered in packaging a stabilizer (or anti-roll) bar system.
Avoid bolts, bar ends, or other unfriendly projections directed at the fuel tank or fuel system. Stabilizer
bar installations should also be evaluated for ride and handling performance.
C-E0402
Avoid static body leans greater than 3/4 inch. This is the side-to-side difference between the heights
of the body side wheelhouse openings. Spacers between the springs and axles can be added to help
balance any lean. The total spacer thickness should not exceed 3/8 inch and must not adversely
affect driveline operating angles. Using a tapered spacer may help control driveline angles. The body
builder is encouraged to avoid as much side-to-side weight imbalance as possible by balancing floor
plans in the original body design, with due consideration for the customer's plans for equipment
placement and cargo loading.
C-E0403
Any suspension component contact with the fuel system is unacceptable. Suspension components
must clear the fuel tank(s) throughout their functional geometry, by 2 inches minimum.
C-E0404
All suspension components loosened, or removed and reinstalled, must be properly reassembled and
torqued in accordance with the Ford Shop Manual.
C-E0600
POWERTRAIN – ENGINE/TRANSMISSION/AXLE
C-E0601
Welding to an axle assembly is unacceptable. This may cause damage to wheel bearings, races, and
seals, as well as weakening of the axle structure.
C-E0602
The installed engine may not have any aftermarket devices added to increase the engine power
rating. In addition, no aftermarket exhaust brake system may be added. Any use of these devices
may void the powertrain warranty.
C-E0700
FUEL SYSTEM
C-E0701
Fuel tank alteration or use of a non-OEM tank is not recommended by Ford on any Conversion Van,
regardless of GVWR, without documentation and rationale to support compliance with all mandated
Federal, State and OEM standards.
Originator: MVE
QVM Guide (Conversion Van Unique)
3
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
C-E0702
The relocation of fuel tanks on vehicles of 10,000 lb GVWR or less is unacceptable on any Conversion
Van without design justification and documented rationale to support compliance with all mandated
Federal, State and OEM standards
C-E0703
Cutting of fuel lines or tapping of the fuel tank is unacceptable.
C-E0704
If the fuel filler hoses or vent hoses are replaced, the new hose material should meet Ford Engineering Specificatio
M2D291-A.
C-E0800
EXHAUST SYSTEM
C-E0801
Any heat or grass shields attached to the OEM exhaust system must be left intact. Any exhaust
component extensions should be similarly shielded.
C-E0900
FRAME
C-E0901
When drilling into the vertical surface of the frame siderail is required, follow instructions shown in
Ford’s Truck Body Builders Layout Book.
Ford E-Series vans employ a body-on-frame, isolated body mounting system (the vehicle body and
frame systems move independently of each other).
C-E0902
Running board mounting systems must be designed so that all attaching points are located at points
on the body.
When running boards are mounted incorrectly (attached to the body and braced to the frame siderail),
chassis NVH is transmitted through the braces and into the body. Additionally, the relative movement
between the body and frame exerts forces through the braces and acts against the attaching points
ultimately loosening them, and possibly introducing corrosion and/or body cracking (refer to CVQP
Quality Bulletin C-5).
C-E0903
The isolation effect of body-to-frame insulators should be maintained. Sofa bed seat belt anchor bar
should not be attached through the rear floor directly to any frame assembly component.
C-E1000
BODY
C-E1001
Corrosion protection is an extremely important factor when considering the overall quality of
automotive products. In addition to the application of rust inhibitor, exterior components which are
installed during the conversion process should be of non-corrosive or properly plated material.
Selection of materials should also consider the corrosive effect of mating dissimilar metals.
C-E1002
Care should be taken to ensure that all added exterior components are properly aligned and include
mounting pads to prevent paint damage which leads to corrosion.
C-E1003
Relocating underbody mounted spare tire to rear door of conversion van exterior is not recommended.
C-E1004
All weather seals included in the conversion package (i.e., raised roof body seal, bodyside panel
window seals) should be water-leak tested prior to installation of interior trim (test may be conducted
anytime after installation of seals if soap bubble/air pressure test method is used).
C-E1005
Interior tables should be designed to remain fixed on vehicle impact so as to avoid occupant injury.
Otherwise they should be labeled “FOR STATIONARY USE ONLY".
Originator: MVE
QVM Guide (Conversion Van Unique)
4
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
C-E1006
A-Pillar mounted spotlights are not recommended as they could lead to an occupant injury in an
accident. If spotlights are added, recertification of C/FMVSS 212 and 219, Windshield
Mounting/Windshield Zone Intrusion, is required for vehicles of 10,000 lb GVWR or less.
GROUND EFFECTS
C-E1007
Rear bumper ground effects must not interfere with access to the spare tire lift mechanism
C-E1008
•
•
•
•
•
Front bumper ground effects should not effect/reduce airflow to the cooling system or automatic
transmission cooler..
Front bumper ground effects with fog lights should utilize the Ford provided "pass-thru" wiring or
be routed in an appropriate manner through the bulkhead.
For mounting added components, the use of mounting pads or Butyl Sealer C9AZ-19554-B or
equivalent between the body and the added components is recommended. Minimize the
corrosive effect of mating dissimilar metals by the careful selection of materials.
Polycarbonate headlamp lenses have a film coating that should be protected. Do not apply harsh
solvents or tape to them.
Equipment mounted near the headlight adjusters should not interfere with aiming adjusters.
HIGH TOP INSTALLATION
C-E1009
•
•
•
C-E1010
Modification of the roof bows, roof panel, etc., for the installation of a raised roof should be
consistent with the Incomplete Vehicle Manual or verified for compliance with C/FMVSS
requirements. Any deviations from the Incomplete Vehicle Manual require engineering analysis,
development prove-out, or testing to demonstrate compliance with affected standards.
Installation of the raised roof should be done according to manufacturer's recommendation.
Leak testing prior to final assembly is recommended to assure sealing integrity and minimize
potential damage to interior trim, etc.
WINDOW INSTALLATION
• When using a template for consistent location of body cutout for bay windows, ensure template is
designed to preclude damage to the paint or structure of the OEM body.
• Protect all body panel cutouts from corrosion with a product containing a zinc-phosphate or
barium-sulfate as the active ingredient. Zinc coating materials should contain a minimum of 92
percent zinc. Two part epoxy coatings are also effective.
• Leak testing prior to final assembly is recommended to assure sealing integrity and minimize
potential damage to interior trim, etc.
INTERIOR
C-E1011
•
•
Overhead consoles should minimize contact points in the head swing areas. Refer to the
Incomplete Vehicle Manual under Section 208 for E-Series recommendations.
Added equipment should allow for the removal of the E-Series engine cover for service.
C-E1012
No controls, switches or display panels may be mounted in the driver or passenger intrusion zone (see
the IVM). This includes the lower instrument panel bolster areas (knee-knock zone).
C-E1013
The OEM air bag supplemental restraint system (SRS) must not be removed, relocated, or altered in
any way.
Originator: MVE
QVM Guide (Conversion Van Unique)
5
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
ENGINE COVER
C-E1014
The use of rivets or adhesives is recommended for the securing of carpeting or other items to the
engine cover. If screws are used, it is recommended that their installation be considered a critical
element of the manufacturing process to ensure that they are minimum in length and pose no threat of
damage to components located within the engine compartment. Items attached to the engine cover
should not interfere with service removal of the engine cover and should provide a minimum of 1/8
inch clearance to the instrument panel to prevent potential squeaks and rattles.
FLOOR COVERING
C-E1015
C-E1015
Cont’
Floor covering should not extend into engine cover seal area or interfere with engine cover mounting
clamps or bolts.
Total thickness of floor covering materials should be kept to a minimum on both the floor and engine
cover in accelerator pedal area to prevent pedal travel restriction.
SEAT, SEAT PEDESTAL
C-E1016
Installation of all seating system components must comply with C/FMVSS (refer to specific standards
and “Design Recommendations” which are included in the Incomplete Vehicle Manual).
C-E1017
Process control-which includes torque specifications-must be applied to the installation of all seating
and restraint system fasteners.
C-E1018
Attention to wire routing is necessary to ensure wires are not trapped under seat frame when installing
aftermarket seats on OEM power pedestals or repositioning seat switches for customer convenience
on captain chairs.
C-E1019
OEM shoulder harness attachment, location, or surrounding structure should not be revised. If other
locations are used, adequate testing and documentation must be conducted to help ensure
compliance with C/FMVSS.
C-E1100
ELECTRICAL
Since the 1992 model year, all E-Series vehicles equipped with the RV Prep Package also include the
Modified Vehicle Wiring Harness. This wiring harness was designed to minimize the need to splice into
OEM circuitry.
C-E1101
Connectors supplied with the RV Prep Package wiring should be protected during the manufacturing
process to ensure metal chips or other debris are not introduced into the connectors which may result
in short circuits or warning light illumination.
C-E1102
Any additions or alterations made to the OEM electrical system should comply with the
recommendations included here and to the guidelines shown in Ford’s Truck Body Builder’s Layout
Book (refer to “Electrical Wiring Section” in the Light Truck Appendix).
C-E1103
The completed vehicle total electrical load must not exceed the maximum output of the alternator at
normal (200°F) operating temperatures.
C-E1104
Modifications to the vehicle charging systems must be done in such a manner as to not cause
electrical overload of the OEM wiring, overcharging of chassis batteries, etc.. The Ford Truck Body
Builders Layout Book or Ford Body Builders Advisory Service should be consulted prior to
incorporating any charging system modification.
Originator: MVE
QVM Guide (Conversion Van Unique)
6
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
C-E1105
Precautions must be taken to minimize the potential for dead batteries and possible damage to vehicle
circuitry. The battery’s negative (ground) cable should be disconnected and positioned so as not to recontact the negative post or the battery should be connected to a battery charger at the various work
stations to ensure the battery’s state-of-charge is not diminished throughout the build process.
C-E1106
Battery voltage should be recorded at final inspection.
C-E1107
Ford makes the following recommendations for wire routings:
• All wiring should be routed neatly to avoid any visual issues.
• All wiring should be secured a minimum of every 6”-12” to avoid any functional issues.
• Wiring should not be routed over the exhaust system or through wheelwell areas where they may
be damaged by tire or road debris.
• All wiring should be protected from fastener damage during the build process and from abrasion
by any unfriendly surface in dynamic conditions.
• Wiring which is located in the passenger compartment should be routed away from high
temperature areas (e.g., floorpan over catalytic converter).
C-E1108
To ensure wires are protected from unfriendly surfaces, all added wiring must be encased in a
protective jacket.
C-E1109
All wire splices should be twisted, then soldered and sealed, or crimped and sealed using the proper
size crimp connector to match the wires being joined.
All electrical connectors, fuses, and circuit breakers which are exposed to hostile environments
(underhood or underbody) should be:
C-E1110
•
•
C-E1111
IMPORTANT: For further information on equipment installation, refer to “Truck Body and Special
Equipment Installation Precautions” in Ford’s Truck Body Builders Layout Book.
C-E1200
MATERIALS, GENERAL
C-E1201
All added vinyl trim, carpet, or other materials must meet or surpass Ford and C/FMVSS 302,
Flammability of Interior Materials, specifications.
C-E1202
Chassis that are stored should be maintained in accordance with the new vehicle storage guidelines in
the Safety and Emission Section of the Ford Body Builders Layout Book and the Ford Authorized
Converter Pool Program Procedures Manual.
C-F0100
DESIGN & MANUFACTURING GUIDELINES - UNIQUE INDUSTRY
MODIFICATIONS
C-F0101
Up-rating of any Ford GAWR, either front or rear, is unacceptable.
C-F0102
The maximum GVWR and GCWR may not be re-rated.
Properly positioned to facilitate servicing.
Properly protected (covered/sealed) to minimize corrosion.
Originator: MVE
QVM Guide (Conversion Van Unique)
7
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
OVERALL FINAL QUALITY INSPECTION
Listed below are quality inspection items that are included on Ford’s CV-QVM rating form. Van
converters are responsible to assure that additional items unique to their product offerings are
included on their final inspection sign-off sheet
C-F0200
FUNCTIONAL ITEMS
Because there is a propensity for the vehicle’s battery to become run-down during the build process, it
is recommended that the battery be inspected and it’s state of charge documented. If battery has
become run-down (no green-eye status), it is the responsibility of the converter to take corrective
action before vehicle delivery.
Because there is a propensity for the vehicle’s battery to become run-down during the build process, it
is recommended that the battery be inspected and it’s state of charge documented. If battery has
become run-down (no green-eye status), it is the responsibility of the converter to take corrective
action before vehicle delivery.
C-F0201
Battery must be inspected for proper state of charge upon receipt of vehicles and before shipping
vehicle to dealer. Refer to CVQP Bulletin C-30.
C-F0202
Driver and passenger restraints should not present any functional or visual concerns. Restraint system
should not be obstructed by added trim or material.
C-F0203
All applicable labels should be present and properly affixed to the vehicle. Some of these labels
include the final stage manufacturer or alterer’s label, air bag label, A/C refrigerant capacity label, and
paint/tape stripe information label. Refer to Ford’s Truck Body Builders Layout Book and Incomplete
Vehicle Manual to determine labeling requirements not expressly noted in this guide.
C-F0204
Air Bag Warning Labels must be properly affixed to sun visors since inflatable restraints are installed
at all outboard seating positions on incomplete E-Series vans equipped with RV-Prep Package.
C-F0205
Seats:
•
•
•
Full fore-aft seat travel should not be restricted.
No “wobbling” should be evidenced.
Arm rest pivot arch should not be restricted.
C-F0206
Sofa bed operation should be smooth and unhindered.
C-F0207
All added switches and controls should be function labeled and illuminated.
C-F0208
Audio and Video systems should be checked.
Originator: MVE
QVM Guide (Conversion Van Unique)
8
Date Issued: April 2, 2002
Date Revised: 06/23/04
Van Conversion
C-F0300
FIT and APPEARANCE ITEMS
To further improve vehicle quality, it is important to inspect the vehicle as a prospective customer will
see it on the dealer’s lot.
C-F0301
The exterior appearance of the vehicle should be inspected:
• Body Finish.
• Body Trim — including graphics.
• Bumper surfaces.
C-F0302
The interior of the vehicle should be inspected:
•
•
•
•
•
•
C-F0303
Overhead control panels.
No extra fasteners/excess material left in unit.
Consoles.
Beverage holders.
Window treatments.
Seals not violated.
The appearance of the carpet/fabric should be inspected:
• Visors.
• Seating upholstery.
C-F0304
Lighting components and fixtures should be inspected:
• Interior lighting.
• Overhead lighting fixtures.
Originator: MVE
QVM Guide (Conversion Van Unique)
9
Date Issued: April 2, 2002
Date Revised: 06/23/04