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NATIONALC A R T E S T

(NCT)M AN UA L2010PassengerVehicles (Up to 8 Passengers)

An tdars Um Shbhilteacht Ar Bhithre

Road Safety Authority

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Governmentof Ireland 2010ISBN9781406424911

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Road Safety AuthorityNatio nal Car Test (N CT) M anual 2010

Covers Type M1 Veh icles

This Manual is not a legal documentand must not be construedas such.

RE V IS IONS

This Manual may be revised and updated from time to time. A current version willalways be availableon the Road Safety Authoritywebsite:www.rsa.ie.

S A F ETY

The methods of testing describedin this Manual are intended to be carried out by trained and competentpersons, working with appropria tesupervisionin suitable premises and with safe equipmentand tools .

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C ontents

Reflectors 34 55

Bodywork 35 56

Tyre Condition 36 60

Tyre Spec ification 37 62

Tyre Tread 38 63

Wheels 39 64

Spare Wheeland Carrier 40 65

Brake Fluid 41 66Chassis/Underbody 42 67

SteeringLinkage 43 69

WheelBearings 44 71

Front Spring s 45 72

Front Suspension 46 74

Brake Lines/Hoses 47 76

ShockAbsorber Condition 48 77

ElectricalSystem 49 78

FuelSystem 50 79

Brake WheelUnits 51 81

MechanicalBrakeComponents 52 82

Brake MasterCylinder/Servo/Valves/Connections 53 83

ExhaustSystem/Noise 54 84

Rear Suspension 55 85

Rear Spring s 56 86

Transmission& Drive Train 57 88

Rear Fog Lamp(s) 58 89

ReverseLamp(s) 59 90

Malfunction Indicators 60 91

Registration Plate Lamps 61 92

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N A T I O N AL C AR T E ST ( N C T ) M A N U AL 2 0 10

IntroductionThe purposeof this manualis to serve as a reference forthose who carry out roadworthinesstests on vehicles with

accommoda tionfor up to eigh t passengersincluding taxi andhackney cab s covered by the Road Traffic (Nationa lCa r Test)Regulations,2009. The manualshould be studied carefullyand used as a reference by persons involved in roadworthinesstesting. Vehic le owners may also find the manual useful in thatit details the inspectionsto which a vehicle should be subjectedand the reasons why it may not be considered tobe roadworthy.

This manual lays down the test method and pass/fail criteriato be adopted forthe compulso ryroadworthinesstest of theabovevehicles.

The Vehicle IdentificationNumberon the vehicle must

correspond with the information on the Vehicle RegistrationFile/Book/LicenceCertificate. Where difficulty is encounteredin locating the Vehicle IdentificationNumber it is theresponsibilityof the applicant to establish the location of thisinformation on the vehicle.

The test is a maintenanceand conditioncheck. A de tailedassessmentof a vehicles design and constructionis not partof the test.

For each item to be tes ted this manual deta ils the methodof tes ting (including Notes) and reasons for failure. A vehicleshould only be assessedagainstthe items listed in this manual.

Method of Testing details the ways in which the tests of

items on a vehicle are to be carried out and the equipmentto be used. When carrying out each test, particular attentionshould be paid to the information given in the Notes sincethis g ivesguidanceon the conductand scope of the test.

Reasons for Failure lists all defects which will result in thevehicle failing. A vehicle may not be failed unless it has one ormore of the listed defects.

The Reasonsfor Failure shou ldbe dete rminedsolelyb yreference to the Method of Test section.

Item 61, Regis tration Pla te Lam ps, is now a Fail Adv isoryitem. Failure of this test will not result in overall failure ofthe vehicle. The owner/presenteris to be advisedof the Fail

Adv isoryitem and urged to have it repa iredas soon as possible.Becauseit is not practicableto lay down limits of wear andtolerance for all componentso f different models of vehicle,testers are expected to use their experienceand judgementinmaking an assessmentof the conditionof componen ts, i.e. isreplacement,repair or adjustmentnecessa ryat time of test.

Any modificationto a vehicle which has safety implicationsmust be approved in writ ing by the vehicle manufacturer.Where this is not possible certificationby an automotiveor mechan icalengineerthat the modificationshave beenassess edand foun d to be safe mus t be provided by the veh icleowner/presenter.

Tyres should be inflated to the required pressure before a test isstarted otherwisetest results may be misleading.

Where the brakes cannot be tested on a roller brake tester, dueto the design of the vehicle, a road test must be carried outusing a decelerometer to evaluate the brake performance.

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M ethodsof Testing andReasonsfor Failure

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N A T I O N AL C AR T ES T ( N C T ) M A N U AL 2 0 10

R E G I S T RAT I O N P LATES

Methodof Testing

1. Check the reg istration plates for secur ity, location, format, legibility, visibility and correct colour.

N O T E S

1. O wne rsof ve hicles reg istered pr iorto 31 Decem be r19 90 ,havethe op tionof co nv ertin gtheirregistratio nplatesto the new format.

2. Veh icles first reg isteredon or after 1 Janu ary19 91For vehicles registered on or after 1 January1991, letters and numbersm ust be black set againsta whi tebackground of reflex reflective material. The flag of the European Communities, the Nationa lity Symbol,IRL, and the Irish languagename of the City/County of registration to be shown. No other marks may

appear on the plate. Any additionaltabs, etc. outside the dimens ionsshown for the registration plate arenot considered part of the plate.

3. Veh icles first reg isteredon or after 1 Janu ary19 87For vehicles registered on or after 1 January1987, letters and numbersm ust be black set againsta whi tebackground of reflex reflective material and minimum dimensionsshould be as shown in the sketches onpage 09.

Veh icles first reg istered pr iorto 1 Janu ary19 87

Reflex Reflec tin gReg istratio nPla tesFront regis tration plates should have black num bers and letters on a white background. Rear registrationplates should have black num bers and letters on a red or white background.

4. Non-Reflex Reflec tin gReg istratio nPlatesFront and rear registration plates should have white, silver or light grey numbers and letters on a blackbackground.

5. Back Lit Reg istratio nN um bers andL et tersWhere registration numbers and letters are back lit the letters and figures must, when illuminatedduring lighting-up hours appear white in the front ident ification mark and either white or red in the rearidentification mark. At all other times they should appear white on a black background.

6. Dimensionsfor le ttersan d nu m be rssh ou ldbe as sho wnin the sk etc hon pa ge12.

7. Where the indented space provided for the number plate is not sufficient to accommodate a standard sizenumber plate, the registration plate and registration letters and numbers may be reduced in size relativeto the space provided for the number plate.

IT EM R E A S O N SF O RF A I L U R E

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D IM E N S IO N S F O R N U M B E R P LATESAll dime nsionsin millime ters

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(Visualcheck) (M ea su redtest)

Pre-testC he ck s(E ngineO ff)

Eng ineO ilLe ve lO k?

Wate rCoolantLevel Ok ?

CamshaftBeltOk?*

Y ES NO

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E X H A U S TS M O K E(D IES E L)

Methodof Testing

(A me tered sm oke test doe snot ap plyto veh icles reg istered before 1st Jan ua ry198 0)

N O T E S

(Vehicle sregistered on or after 1st Ja nu ary19 80 )

1. All diesel engine tests must be perform edaccording to EU Directives. Where an automatictransmissionisfitted , the manufacturers guidel ines should be consu lted .

2. No smoke test should be carried out without having done the pre test check detailed on page 11.

3. It is absolutely essential that the engine is at normal operating temperature before carrying out a smoketest. Testers should ensure that engines are not warmed up by being left idling or at half throttle . Theyshould be warmed up by normal driving.

4. Engines left idling for any length of time will show a high smoke opacity reading.

5. When carrying out this test the throttle must not be blipped.

6. Exhaust emissionstests should not be performed on a vehicle where the oil level is wel l over the dipstickFull mark.

7. Where the oil level is below the minimum level, the exhaust emission test should not be performed if it isnecessaryto purge the engine.

8. Where a diesel engine is at the correct operating temperature and has been correctly purged and the firstthree readingsare at or above 9.99 , the exhaus t emissionstes t may be aborted.

9. Where a vehicle is producing black smoke to such an extent that the smoke meter might be damaged,the vehicle should be fai led without carrying out the normal smoke test (see Test for vehicle registeredprior to 1980 .)

10. Where a vehicles eng ine speed is limited when the vehicle is stationary, the smoke test may be carriedout at the restricted rpm.

Veh icles reg istered on or after 1st Ja nu ar y19 80

1. Check visually that the emissioncontrol system is completeand properly connectedand that there are no leaks in theexhaustsystem.

2.With the eng ine at norm al operating temperature, raise the engine speed slowly to 2,500 rpm or half the engine manufacturersrecomme ndedgovernedspee dwhicheveris less and hold for 20 secon dsin order to purge the exhaustsystem. If the engineemits any unusualnoises the test should be abandoned. Slowly raise the engine speed to its maximum rpm and note if thegovernor operates within the vehicle manufacturers recommendedrpm setting. If not the test should be discontinued. Do notho ld the engin eat max im umrpm for any lengthof time .

3. Connectthe diesel smoke meter to the vehicle followingthe smoke meter manufacturers instructions. Depress the acceleratorpedal firmly from the idling position to the maximum fuel delive ry position follow ing the prompts of the smoke meter. Thesmoke meter is programmed to ignore the first reading. The operation is repea tedand if the reading on this occas ionis lessthan 60% of the acceptable limit the test is ended. If the reading is not less than 60% of the acceptable limit, the operation isrepeated. If the average of this and the previous reading is within the acceptable limit the test is ended. If the averagereadingsare not w ithin the limits the operation is repeated up to a max imum of three more times taking the average of the last tworeadings after which the test is ended.

Vehiclesregisteredbef ore1st Ja nua ry19 80

4. For these vehicles, the exhaus temiss ionshould be assessedwhile driving the vehicle in the test area or test lane. Undernocircumstancesshould the eng ine rpm be taken above that required to drive the vehicle through the various tests.

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1 Where the average smoke meter reading is higher than

2.5m-1

in the case of naturally asp irated diesel eng inesand3.0m-1 in the case of turbo chargedor superchargeddiesel engines.

2 Where the maximum attainable engine speed is less than or equa l

to 90% of the maxim um speed specified by the manufacturer.

3 Where the average smoke meter reading is higher than 1.5m-1.

4 The exhaustemiss ionis coloured black haze or darker.

5 Emissioncontrolsystem leaking,incompleteor incorrectlyassembled .

6 Engine idle speed incorrect(e.g. 100 rpm

of manu facturers stated speed).

Note: If the fuel pump seal is missing and the maximum rpm

achievable is less than 90% of the manufacturers stated maximum

rpm, it should be consideredthat the fuel pump has been adjusted

to pass the test and the vehic le should be failed on this test.

Wherea veh iclehas passedthe emissionstest and

the exhaust system is later found to be leaking,

the exhaustread ingsshou ld be overridden.

The date of first registration will be used to provide the test

standard. If the station manager has informationto prove

that the car was built to a less stringentstandard (such as

indicated by the year of manufacture), he may pass the

car if it would have passed the less stringentstandard.

If the eng ine has been changed, apply the standards to which the

car was originally built, not the year of manufacture of the engine.

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E XH A U STC O /H C /LAM B D A(Thisitem doe snot ap plyto ve hicles reg istered before 1st Januar y19 80)

Methodof Testing

1. Check visua lly in the case of4 stroke s parkignitio neng ines(petrol or gas) that the emissioncontrol system is completeandproperly connectedand that there are no leaks in the exhaust system.

PreJan1994Registrations

2. With the engine at normaloperatingtemperature connectthe CO/HC mete r as per manufac turers instructions. Raisetheengine speed to approximately 2,500 rpm and hold for 20 seconds. Allow the engine to return to idle and the emissionsreadingsto stabilise. Note the carb on monoxide and hydrocarbon content of the exhaust gases at norm al idle speed.

Post Jan1994Registrations

3. For vehiclesfirst registeredon or after the 1st Janu ary1994 raise the enginespeed to 2,50 0 rpm or to a speed spec ifiedby theveh icle manufac turer and hold for a minimum of 30 seconds. Check the HC , CO and Lamb davalues. If the exhaustemissionsare not within the speci fied limits with the vehicle engine at norma l operating temperature raise the engine speed to 2,500rpm or to a speed specifiedby the vehicle manufacturer and hold for 3 minutes and note HC, CO and Lambdavalues. Allow theveh icle eng ine to return to normal idle speed and the exha ust reading to stabilise and note the CO reading .

N O T E S

1. When checkingexhaustemissions,the vehicle must be conditionedin accordancewith the vehiclemanufacturers recommendations.

2. Hybrid vehicles shou ld be viewed as an electric vehicle and will not require an exhaust emissionstest.

3. For the fol lowing Rover vehicles: a) Mini 1300 carburettor and open loop three-way catalyst, b) MetroRover 100 1100 carbure ttorand open loop three-waycata lyst,first registeredon or before 31 December

1994, the exhaustemissionlimit for CO is 3.5% and for HC is 1200 ppm. Where a vehicle meetsthe COlimit but fails the HC limit, the inspector must perform a further HC test at 2000 rpm. If the vehicle meetsthe HC limit at 2000 rpm, it is considered to have met the requirements.

4. For Suzuki Cultas, the maximum allowable CO value is 4.5% and the maximum allowable HC value is1200 ppm.

5. Where it can be estab lishedthat the vehicle manufacturers recomm endations on exhaust emissionsarehigher than those listed in the reasons for failu re then the manufacturers figure should be the crite riaused when decidingwhetheror not the vehicle passes.

6. For veh icles testedoperating on L.P.G. the hydrocarbonreading must be divided by the propane/hexaneequivalentfactor (PEF ) which is marked on the hydrocarbontest equipment.

7. Where vehicles are fitted with twin exhaust systems the higher of the two should be taken.8. A HC test is not required on vehicles operating on CNG.

9. This test should not be carried out where:

(a) the oil warning light remainson with the engine running.

(b) the oil level is below the manufacturers minimum level.

(c) the oil level is above the manufacturers maximum level.

10 This test does not applyto two-strokeor rotary piston (Wankel)engines.

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1 Leaking.

2 Emissioncon trol system leaking, incomplete

or incorrectly assembled.

3 Obviouslyoutside veh icle manufacturers recommendations ( 100

rpm or 10%ofmanufacturers stated speed whicheve ris greater.).

4 For vehiclesfirst registered before 1st day of October1986, the

carbon monoxidecontent is more than 4.5% at idling speed.

5 For vehiclesfirst registered on or after 1st day of October

1986, up to 31st December1993, the carbonmonoxidecontent at idling speed is more than 3.5%.

6 For vehiclesfirst regis tered on or after 1st day of January1994,

the carbon monoxidecontent at idling speed is more than 0.5%.

7 For vehiclesfirst regis tered on or after 1st day of January1994,

the carbon monoxide content at 2,500 rpm or at a speed

specified by the vehicle manufacturer is more than 0.3%.

8 For vehiclesfirst registered on or after 1st day of July 2002

the carbon monoxide at idling speed is more than 0.3% .

9 For veh icles firs t registered on or after 1st day of July

2002 the carbon monoxidecontentis more than 0.2%

by volume at either an engine speed of 2500 rpm or at

a speed specifiedby the vehicle manufacturer.

10 For vehiclesfirst reg iste redbefore 1st October, 1986 , the

hydrocarboncontent at idling speed is more than 1,000 ppm.

11 For vehic lesfirs t regis tered on or after 1st day of October

1986, up to 3 1st December1993,the hydrocarbon

content at idling speed is more than 750 ppm.

12 For vehicles firstregis teredon or after 1st day of January

1994, the hydrocarboncontentat 2,500 rpm or at a speed

specified by the vehicle manufacturer is more than 200 ppm.

13 For vehicles firstregis teredon or after 1st day of January

1994, the lambda value at 2,500 rpm or at the speed

specified by the vehicle manufacturer is not 1 .03 or

within the vehicle manufacturers recommendation.

14 Excess iveexhaustsm oke likely to affect other road users.

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E XH A U STC O /H C /LAM B D A

I T EM R E A S O N SF O RF A I L U R ENote:For kit cars built before 1st Janua ry2000,

use the pre-1994 em iss ionsstandards.

Where a kit car is presented for a tes t, a declaration is

required from an automotive Engineer/Assessorstating the

make, year of manufactureof the engine, and the exhaust

emissionvalues stated by the engine manufacturer.

The date of first registration will be used to provide the

test standard. If the test centre manager has informationto

prove that the car was built to a less stringent standard (such

as indicated by the year of manufacture), he may pass the

car if it would have passed the less stringent standard.

If the engine has been changed, apply the standards to which the

car was originally built, not the year of manufacture of the engine.

For cars fue lledby CNG (CompressedNatural Gas)

do not apply a HC standard. This will prevent false

failures from excessivemethaneemissions.

The HC (hydrocarbon)will only be checked at high idle

on cars equipped with catalytic converters.

Imported and used vehicles first registered after 1994 that are not fitted

with a catalyticconvertershould be tested againstpre-1995 values.

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S ERV IC EB R A K EPEDAL

Methodof Testing

SE ENOTE (1)B EL OW

1. Check the anti-s lipprovisions on the pedal pad .

2. Examinethe conditionof the pedal.

3. Check the fixing of the pedal pad to the pedal and the fixing of the peda l to the operating lever.

4. Move the peda l from side to side and examine the condition of the peda l pivot bearing/bush.

5. Depress the pedal to check for fou ling on parts of the vehicle.

N O T E S

1. Before carrying out this inspection,chock the road wheels.

2. Brake pedals should not be rejected for not having a pedal rubber if they were not designed to have one.

I T EM R E A S O N SF O RF A IL U R E

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S ERV IC EB R A K EO P E RAT IO N(Inspection inside theVehicle)

Methodof Testing

1. For hydraulic systems, fully depress the pedaland keep it depressed undera steadypressure . Note whether the pedal tends tocreep down.

2. For hydraulic sys temsrelease the handbrake, depre ssthe pedal and note the extent of travel of the brake pedal and whetherthere is sponginess.

3. On some vehicles the action of the brakes is assis tedby vacuum from the engine. In such cases depletethe vacuum byapplying the service brake a numberof times with the engine switchedoff. Fully apply the service brake, start the engine andnote whether the pedal can be felt to dip.

4. If the veh icle is fitted with a brake anti-lock system, check the warning lamp.

N O T E S1. The check procedureon Anti-LockBrake System swill vary according to the type of system fitted.

The manufacturers handbookshould be consultedfor the correctcheck procedure.

I T EM R E A S O N SF O RF A I L U R E

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M E C H A N I C A LB R A K EH A N DLE V E R(wherefitted)

Methodof Testing

SEENOTESBELOW

1. Examinethe cond itionof the brake lever and its position.

2. With the brake lever in the off position:

(a) note the amount of side play in the lever pivot by moving the lever from side to side.

(b) check the conditionof the ratche t and pawl mechanismpivots.

(c) check the safety guard.

3. Apply the brake lever slowly and check the effective operation of the pawl mec hanismby listening for defin ite and regularclicks as the paw l mov es over the ratchet teeth.

4. When the brake is fully applied:

(a) knockthe top and each side of the lever by hand and check that the lever is held in the on position.

(b) check that the lever is not at the end of its perm itted travel and that there is no fouling of adjacent parts.

N O T E S

1. Before carrying out this inspection,chock the road wheels.

2. In som e cases it is not possible to check these items completely from inside the veh icle, but only toobtain an indication of their condition. If a defect is suspectedwhich cannot be verified from inside thevehicle the inspection must be continued from a position underneaththe vehicle.


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N O T E S

1. Seats include child seats or child restraint systems

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1 Controlinsecure.

2 Horn insecurely mounted.

3 Not working correctly.

4 Not working or not fitted.

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W I N D S C R E E NW IPE R SA N DW A S H ER S

Methodof Testing

1. Switch on the windscreen wipers and washers and check for operation and security and that the wipers move at an

appropriate speed over an arc of the windscreen glass which is sufficient to give the driver an adequate view.2. Check the wiper control.

3. Examine the conditionof the wiper arms and blades. Check that the springs are not weak or broken.

4. Check wiper linkagefor wear.

5. Check that the windscreenwasher(s)functionsatisfac torily.

N O T E S

1. Washers will be consideredas being fitted if there is any part of a washer system fitted.

2. This test only applies to front windscreens.

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G L A S S

Methodof Testing

1. Check the condition and security of the windscreen and all side and rear windows.

2. Checkthat wherethe windscreenis made of glass it is marked as safetyg lass.

3. Check that there is an adequate view from the d riving seat and that it is not in terfered with by objec ts or stickers.

4. Check that in the case of veh icles first regis tered on or after 1st January1986 the windscreen is made of laminated safety glassand marked as shown on the attachedScheduleI overlea for to an equivalent stan dard as shown in Fig. 1 below.

5. Where windscreens,side or rear windowsare fitted with glazing materialother than safety glass the vehicle owner shallprovide a certificate from the manufacturer or insta ller stating that the glaz ing material is not likely, if fractured, to producefragmentscapableof causingsevere cuts. In the case of rally cars, this may take the form of a note from the TechnicalCommissionerof the RIAC in the vehicle log book.

6. Check that the drivers window operating mechanism is function ingproperly.

7. If an inspec tordeem s that the windscreenor front side windows are excessivelytinted, the level of light transmissionof the window should be tested using light meter capable of measuring the amount of light transmitted through thewindscreen and the side windows along side the driver to an accuracy of 3% and suitable for reliable use in aninspectioncentre environment.

C O U N T RY S A F E T YG L A S SSTA NDA R D

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1. Windscreen repairsare acceptable providedthey meetBS Codes of PracticeBS AU242 and BS AU25 1

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* This number varies and relates to thecoun try which issued the approval.

** In association with the standard marka serial numberassignedby the issuingcountry is shown in this position.

NOTE

The absenceof II or III above or beside the approvedstandard mark indicates that the glass is not laminated.

B.S. 857-2 or

B.S. 5282or

B.S.A U 17 8

See also note below

NOTE

TheB.S. must be accompaniedby the word laminatedor the let ter L, WL or WLT. The absenceof thesewill indicate that the glass is not laminated.

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* This numbervaries and relates to the countrywhich issued the approval.

** In associationwith the standardmark a serial numberassignedby the issuing countryis shown in this position.

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ZONEA Damagethat can be containedw ithin a 10mm diameter circle (maxim umof two defects provided they aremore than 100mm apart).

ZONEB Damage that can be con tained within a 20m m diameter circle or hairline cracks up to 30mm long (maximum of twodefects providedthey are more than 100mm apart).

ZONEC Damagethat can be containedw ithin a 40mm diameter circle (maxim umof two defects provided they are more than100mm apart).

N O T E S

1 The vehic le should be failed where damageis beyond the above limits.

2 Dam agedwindscreensmay be repairedprovidedthe repa irs mee t the requirementsof Codes of PracticeBS AU2 42and BS AU2 51 .

3 Light scratching which does not obscure the drivers view should be ignored.

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R E A RV IEWM IR R O R (S)

Methodof Testing

1. Check the cond ition of mirrors fitted to the vehicle as standard equipmentto see that the reflecting surface is not

deterioratedor broken so as to impair the drivers view.2. Exam inethe security and conditionof each mirror mountingbracket.

N O T E S

1 Estate and hatchback cars are required to be fitted with an exterior rear view mirror on each sideof the vehicle.

2. All other vehicles should be fitted with an internal rear view mirror.

3. Where a vehicle does not have two exterior mirrors, there must be clear evidence on the day that thevehicle was originally fitted with two exterior mirrors or it cannot be failed on this point. If there is any

doubt, the benefit of the doub t must be given to the vehicle owner.4. A vehicle must not be failed on mirrors fitted in addition to the legally required mirrors.


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1. Check that a speedometeris fitted , work ingand can be easily seen from the driving seat.

2. Check that the speedometercan be illuminated.

N O T E S

1 The speedometerfunctions check is limited to the movement of the vehicle within the test area.


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S A F E T YB ELT S(Th isitem do esno t ap plyto ve hicles reg isteredbefore the 1st day of June1971)

Methodof Testing

1. For vehicles registered on or after the 1st day of June 1971, check that a lap and diagonaltype safety belt is provided for thedriver andfront outer passengerseat.

2. For veh icles regis tered on or after the 1s t day of Janua ry1992,check that all oute r forward facing seats are provided w ith a lapand diagonaltype safety be lt and all other forward facing seats are provided with a lap and diagonal or lap type safety belt .

3. Pull each safety belt webbing against its anchorage and see that it is properly secured to the veh icle struc ture.

4. Examinethe cond itionof all safety belt webbingfor cuts or obvious signs of deterioration. In the case of the retractable typesafety belt ensure that the belt is fully extended during this examination.

5. With the seat unoccupied,fasten the safety belt buckle and check that the adjustmentmechanismfunctionsproperly . In thecase of retractablebelts ensure that all the slack is removed and by pulling the belt quickly check that the locking mechanismoperates. Attempt to separate the fastened belt at the buckle and chec k that the belt can be released when requ ired.

6. Exam ine the cond ition of the attachment and adjustmentfittings on each belt for distortion or fracture.

7. As far as is practicablewithout dismantling ,check the condition of the vehic le structu re in the vicinity of the safety beltanchorage points. The conditionof floor mountedanchorage points may best be inspectedfrom undernea ththe vehicle.

N O T E S

1 Where a vehicle is fitted with seat belts which can only be checked for operation by a road test, it willnot be necessaryto check the operation of the rear seat belts. Both front seat belts must be checked foroperation; however, the visuals shou ld make clear to the owner that the rear seat belts have not beenchecked for operation .


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S T E E R I N GW H E E LP LAY

Methodof Testing

1. With the road-wheelsin the straight-ahead position, lightly turn the steering wheel to the left and righ t as far as possible and

note the amount of free play before the road-wheelsmove. (If power steering is fitted the engine should be runn ing).2. Attempt to lift the steering wheel in line with the steering colum n and note any movementat the centre of the steering

wheel or the steering column.

3. Push stee ring wheel away and pull it towards you r body, and note the movementof the steering column and itssecurity of mounting.

4. Exam ine the universal joints/flexiblecouplings for wear, security or deter ioration.

5. Examinesteeringlock where fitted (see Item 15 for reasonsfor failure).

6. Check the presenceand securityof retainingand lockingdevices .

N O T E S

1. Where a steering mechanism is fitted with flexible couplings care must be taken to distinguish betweenplay due to wear, and apparent play due to the construc tionof the mechanism.


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D O O R /LO C K S/AN TI-T H E FTD E V IC E S

Methodof Testing

Examine the general co nd itio nof all do ors .

1. Open each door and check the secu rityof catches and rece ivers.

2. Close the door and, without using the handle, note whetherthe door primary and secondarycatches hold the door closed.

3. By open ingan d clos ing each doo r note whetherthe door pillars are sound (see Item 35 for reasons for failure).

4. If the vehicle is fitted with sliding doors examine the condition of the runners and tracks and actuating mechan ism.

5. Check that the steer ing lock is not fouling the steer ing mechanism when the ignition is switched on.


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1 Worn, insecure, sticking, fouling or likely to fail.

2 Servo or electricaldevices defective.

3 Wiring insecure, insulation damaged, likely to short circuit or fail.

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FR O N TW H E E LS ID ES LIP

Methodof Testing

Drive the R/H front whee l slowly and straight over the side slip plate without moving the steering wheel or applying the brakes

and note the reading.

N O T E S

1. When exp lain ingdefects to vehicle owners or garages, side slip may be refe rred to as steeringgeometry.


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R E A R W H E E LS ID ES L IP

Methodof Testing

Drive the R/H rear wheel slowly and straight over the side slip plate without mov ing the steer ing wheel or applying the brakes and

note the reading.


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More than 30% imbalancebetween L/H and R/H suspension.

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More than 30% imbalancebetwee nL/H and R/H suspensions.

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S E R V I C EB R A K EP E R F O R M A N C E

Methodof Testing

RollerBrake Test

If the Vehicle is of a type wh ich can be tes ted on the roller brake test machine proceed as follows.

1. Pos ition the vehicle so that the wheels of eac h axle can in turn be placed on the brake tes t machine rollers.

2. Drive the veh icle onto the roller brake tester and follow ingthe prom pts of the brake teste r programme apply the serv ice brake.

3. Check that the brake can be applied progressively and when released does not show any abnormallag.

N O T E S

1. Tyres must be correctly infla ted and the gear selec tor shou ld be in the neutral position.

2. The testing of vehicles fitted with ice studded tyres will damage the brake tester roller friction surface. It

is advisableto ensure before the roller brake test that the tyres are not damagedand are free from stonesembeddedin the tread.

3. Vehicles having automatic transmissionmust not be tested with the gear selector in the P parkposition.

4. Occasionswill arise when the required brake efficiency is just obtained or just exceeded without lockoccurring but the tester knows that a higher performancefigure is normally obtainable for the type ofvehic le being tested. In such cases althoughthe vehicle has passed the brake performancetest, thetester should advise the owner that the braking system appears to be in need of adjustmentor repair.

5. For vehicles with servo assisted or power braking systems, the eng ine must be running (idling) when theservicebrake is tested.

6. In some cases it may be necessaryto chock the road-wheelsof the vehicle during a roller brake test.

7. Care should be taken to ensure that tyres are free from mud , stones, oil, or water and that brake testerrollers are in good condition to ensure that premature wheel slip does not occur.

8. The use of a roller brake tester is not appropriateon hybrid vehicles or on vehicles with a permanentlyengaged four wheel drive, limited slip differential or belt driven transmiss ion.

9. Where a vehicle cannot be tested on a rolle r brake teste r because of additionalspoile rs fitted , they mustbe removed by the owner/presenter before the test. A decelerometertest will not suffice inthis situation.

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S E R V I C EB R A K EP E R F O R M A N C E

Methodof Testing

DecelerometerTest

If the vehicle is of a type that cannot be tested on the roller brake test machine it shou ld be subject to a decelerometertest as follows:

1. With the vehicle on a reasonably level road place the decelerometer on the floor of the veh icle and following themanufactu rers instructionsset it in the zero position.

2. Have the vehicle driven at a speed of approximately 20 30 M.P.H . (32 48 km/h). Have the service brake applied firmly andnote the reading on the decelerometer.


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S ERV IC EB R A K EIM B A L A N C E

Methodof Testing

1. Normallythis test and the service brake performancetest will be carried out concurrently and the same general precautions

apply (see Methodo f Testingand Notesfor serv ice brake perform ance).2. RollerBrake Test

With the roller brake test machine driving the wheelsof each axle in turn, apply the service brake slowly and note the brakingeffort indicatedfrom the brake on each road-wheel.

3. Ro adTes t(if ca rriedout )Where a road test is carried out, this should be done in traffic-free circumstancesat a speed of 48km/h (30mph)Note whetherthe veh icle pulls to one side when the brakes are applied and if there is any evidenc e of brake drum/disc ovality.


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P A R K I N GB R A K EP E R F O R M A N C E

Methodof Testing

RollerBrake Test

1. Normallythis test will follow the service brake test and the same generalprecautionsapply (see Method of Testing andNotesfor ServiceBrake Performance).

2. With the roller brake test machinedriving each road-wheel,apply the parking brake slowly until each road-wheelis just atthe point of slip relative to the rollers, or until sufficient braking is achieved whichever occurs first. Note the braking effortindicatedfrom the brak e of each road-wheel,and calculatethe total braking available. Calcula tethe braking efficiency as apercentage of the vehicle test weight.

3. If the park ing brake is a transm issionbrake, all wheels on the axle that are braked by the transmiss ionbrake mus t be driven bythe roller brake test machine at the same time.

DecelerometerTest

If the vehicle is of a type which cannot be tested on the roller brake test machine,it should be subject to a decelerometer

test as follows:

With the vehicle on a reasonablylevel road, place the decelerometeron the floor of the vehicle . Follow the manufacturersinstructionsand set it in the zero position.

Drive the veh icle at a speed of approximately 32km /h (20mph). Apply the park ing brake and note the reading

on the decelerom eter.


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PA R K IN GB R A K EIM B A LA N C E

Methodof Testing

1. Normallythis test and the parking brake performancetest will be carried out concu rrentlyand the same generalprecautions

apply (this test is not relevant to transmissiontype parking brakes).

RollerBrake Test

2. With the roller brake mach ine driving all the wheels of each axle in turn, apply the parking brake and note the braking effortindicatedfrom the brake of each road-wheel.


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TO W INGB R A C K ET/COUPLING

Methodof Testing

N O T E S

1. This inspection applies only where a vehicle is fitted with equipmentfor towing trailers.

DrawingCoupling

1. Exam ine the drawing vehic le coup ling ball/jaw and pin. Note the conditionof these componentsand ensure that they are freefrom excess ive wear, distortion and/or fracture.

2. Check the body of the couplingfor wear, distortionor cracks.

3. Examinethe cross/chassis mem berto which the coupling is mounted,paying particularattention to security and cracks.

4. Check that the couplingassemblyis securely attachedto the vehicle.

5. Check that locking or safety devicesare in positionand workingcorrectly.


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STO P LA MPS

Methodof Testing

With the ignition and rear lights switched on, apply the service brake and check the stop lights for visibility, colour,intensity and security.

N O T E S

1. For the third (high) brake lamp, Reason for Failure (5) does not apply.

2. Additionals top lamps (other than those fitted by the vehicle manufacturer)are not part of the test.


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1 Not working or faulty.

2 Missing or not clearly visible.

3 Not red in colour.

4 Lens broken (crack separated or white light show ing)or missing.

5 Not of the same dimensionsand intensity.

6 Insecurely mounted.

7 Not fitted symmetrically.

8 Contains water / moisture.

Note:For LED matrix lamps, fail for reason (1) above if lessthan 50% of LEDs are work ing in any single unit matrix.

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IN D ICATO R S /T E L LT A L E S

Methodof Testing

Switch on the d irection indicators and check that:

1. each indicatoris working correctly and is clearly visible.

2. each indicatoris of the correct colour and securely mounted.

3. there is a way for the driver to be readily aware from his seat that each direction indicator is func tioning.

N O T E S

1. The presence and operation of four way flashers or hazard warning flashers is not a part of the test.Where repeater indicators are fitted as standard equ ipment,these must be working.


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SID ELA M PS(FrontPositionLam ps)

Methodof Testing

SideLamps

Check that the two lamps showing a whi te light are fitted symmetrically to the front of the vehicle and:

1. when illuminatedare clearly visible.

2. are securely fixed.

N O T E S

1. When a side lamp is incorporated in a yellow headlamp, effectively producinga yellow side lamp, this isacceptable. In this case, the lamps on both sides of the vehicle must be the same colour.


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H E A D L A M PCONDIT ION

Methodof Testing

1. With the headlampsswitched to main or dipped beams, check that each headlampshows a light of the same colour (white or

yellow) of such intensity as to sufficiently illuminate the road in front of the vehicle.2. Check the conditionand colour of the headlampglass and reflectors.

3. Check the operationand security of the headlamp, dip switch and the headlampmain beam warning light.

N O T E S

1. Headlampsshould cons ist of either two or four lamps, or one lamp in the case of an electric vehicleincapab le ofexceeding40km/h (24mph).

2. Headlampsare not required to be e-marked.

3. Where a dipped beam is so far out of focus that it cannot be picked up by the headlamptester, then itshould be failed.


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H E A D L A M PA IM

Methodof Testing

Align the headlampbeam-setterin front of each headlamp in turn, and with the headlamp emitting the dipped beam or the main

beam as appropriate (see Notes below), determine the % gradient of the highest intens ity of the beam relative to the plane onwhich the vehicle is standing.

N O T E S

1. Headlampsfall into three categoriesas follows:

i EuropeanType Head lamp checked on dip beam (see figure 1 for methodof test).

ii British -AmericanType Headlamp checkedon dip beam (see figure 2 for methodof test).

iii British-AmericanType Headlamp checked on main beam (see figure 3for method of test).

2. Tyre pressures should be checked and corrected if necessarybefore the headlampaim is checked. Thevehicle and the beam-settershould be located on the special headlamp aim checking area withinthe test premises.

3. Any headlamprange adjuster must be in the basic setting.

4. If a vehicle is presented with left hand drive headlampsand beam masks, the masks must be installed toensure they effec tivelyblock any light projection above the 0% horizontal reference line. This would thenshow a pattern similar to a mirror image of Fig. 2 and can be checked as on that guide.

5. On veh icles fitted with hydropneumaticsuspens ion,the eng ine must be idling during this test.

6. The vehicle shou ld be tested without a person in the drivers seat. If the reading is 0.2% to the limit(between -0.4% and -0.2%), the test shou ld be carr ied out with an occupantin the seat. This reading willbe stored in the test results.


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H E A D L A M PA IM

Europe anTypeHe adlam p checked on dippedbeam .

The lens may be circular, rectangu laror trapezoidal in shape. It will usually have a segment shaped pattern moulded into theglass. It may be marked with a 2 and an arrow, or a C above either an E or e. On dipped beam , it will produce a pattern

similar to the figure below..

0-850mm

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0%

Check on the dipped beam and determinethat:

1. the upper edge of the hot spot lies between the 0% and 2.75% horizontal lines shown on the screen.

2. the right hand edge of the hot spot lies between the 0% and 2% vertica l lines .

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H E A D L A M PA IM

British-AmericanTypeHeadlampchecked on main beam.

The lens of this type of headlampis circular and likely to be of the sealed beam construction. It may be marked with a 1 and anarrow. It will not have a C above either an E or e. The dipped beam pattern will not match either of the figures shown on the

previous pages but the main beam will be similar to the figure below.

0-850mm

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AUXIL IARYLA M PCO ND ITIO N AN D PO SIT IO N

Methodof Testing

1. Check that each auxilia ry lamp fitted is securely and correctly fixed to the vehicle.

2. Check that the switchingmechanismis functioningcorrectly and that any auxiliary lamps set in the headlampmain beamposition are extinguishedwhen the headlampdipped beams are brought into operation.

N O T E S

1. Where aux iliary lamps are found to be inoperative, this should not be considered a reason for failure.

2. A broken glass on an auxil iary lamp or fog lamp is not a reason for failure unless the crack or break islarge enough to insert a shee t of paper as used in the test.


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AUXIL IARYLA M PCO ND ITIO N A ND PO SIT IO N

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A U XIL IARY LA M PA IM

Methodof Testing

Align the headlamp beamsetterin front of each lamp in turn, and determ ine the direction of the highest intensity of the beam

relative to the plane on which the vehicle is standing.

N O T E S

1. The agreed procedure if there are auxiliary and fog lamps installed: Auxiliary light carry out in the highbeam position.

2. Where a vehicle is fitted with an auxiliary lamp and a fog lamp the requirement is to check both lamps.


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R E F L E C T O R S

Methodof Testing

Rea rRefle ctors(re qu iredon al l ve hic les )

1. Check that two red reflectors are fitted symmetrically to the rear of the veh icle.

2. Che ck that each reflecto ris secure, completeand operates in an effective manner.

SideReflectors (if fitted)

3. Side reflectors,if fitted, mus t be amber in colou r; however, the rearm ostside retro-reflector can be red if it is grouped or haspar t of the light emitting surface in common with the rear position lamp, the rear end-outline marker lamp, the rear fog lamp,the stop-lamp or the red rearmost side-marker lamp.


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B ODY W O R K

Methodof Testing

Examineprimary structural components(including floor pan) for cracks, security, damage or rust. Checkwhererepairshave

been carried out that there is an eng ineers report stating that the original strength and safety of the vehicle has not beencompromis ed and that any welding or brazing has been carried out using good engineerin gpractice. Check from both front andrear that the body is sitting squarely. Examineall secondarystructuralcomponentsfor security, rust or jagged edges. Checkthatbum pers,guards and body panels are secure and not likely to injure pedes triansor other road users.

Check that fumes are unlikely to enter the vehicle e.g. torn gear lever boots.

Check that the bonnet and boo t lid catches are operating properly. In the case of front opening bonnets,ensure that the safetycatch is fitted and operating properly.

Prima ryStructu re

1. Primary structure includes any structure or componentwhich, if it collapsed,would make the vehicle uncontrollable or wouldconsiderablyreduce occupantsafety in the event of an accident. Examples of componentsin this category are illustrated onpage 57. Areas within 100mmof doorlocks or hinges would be consideredprimarystructure.

SecondaryStructure2. Secondarystructure includes any structure or componentwhich, if it collapsed,would not immediately affect a vehicles

contro llabilityor the pro tection provided by its built-in safety systems. Normally, rust would not be a cause for rejection inthese com ponentsbut extensiverust is usually either hazardous to personsin or near the veh icle becauseo f its sharp edge s orbecauseexhaustfumes can get into the vehicle. Extensiverust must therefore be rejected. The illustration on page 57 showsexamples of secondarystructure.

N O T E S

1. A missing or damagedmud flap is not a reason for failure.

2. The judgem entto be made is whether or not the manufacturers original strength has been maintained.Where a man ufacturer has used brazing in some area of the manufacturingprocess, repa irs using asimilar processand to a similar standardof workmanshipis acceptable. Using brazing to repair chassismembe rsis not acceptab le.

3. Where a boot is completelyfull, an examinationcannot be made and therefore a pass certificatecannotbe issued.

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35

1. Main structu ralmem berssuch assub fram esand chass israils .

2. Su sp ens ionmo unti ngsan d parts.3. Steering component mountingpoints.4. Door sills and pillars .5. Door hinges and latch mountingpoints.6. Sea tanch oragepoints.7. Sea tbe lt anch oragepoints .8. All floor panels.9. Boot floor.10. Bulkheads.

1

1. Wings or bumpers.2. Roof.3. Bootlid,bonne tand doors (areas

within 100 mm of mountingand lockingpoints are primarystructuresand must befree of advanced or extensive rust).

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35B ODY W O R K

Surface Rust

Rust removableby rubbing. Whencleaned itreveals a smooth cleansurface.

PARENT METAL

Advanced RustRust concentrationor pits.Removal leaves pit marks whichcan only be eliminatedby removalof parentmetal.

PARENT METAL

Extensive RustRust flakes - removalof whichleavesa very rough or holedsurface. Pits go righ t throughandcause eruptionon far side.

PARENT METAL

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7 Vehicle manufacturers original strength orsafety obviouslynot maintained.

8 Two halves of vehicles joined together where no certificationis available from a competen tperson (see Notes below).

N O T E S

1. Certificationmeans the vehicle is certified by a competentperson that:

(a) the vehicle was checked on a body jig and is in line with the manufacturers specification.(b) any welding has been carr ied out by a qualified welder.

(c) the front and rear brakes are compatible.

(d) the front and rear suspensionsystemsare compatibleand

(e) the vehicle has been road tested and found to be stable.

A competentperson would include a vehic le manufacturer, a mechanical or automotiveeng ineer, anautomotiveassessoror equ ivalent.

2. The bodyworkcheck includesan examinationof the boot. Where this cannot be opened or con tainsitems which would make the examination difficult, the bodywork check is considered to have not been

completedand the vehicle cannot be passed.3. Glued structuralcomponentsare not acceptableunless they are consistentw ith the manufacturers

design and to a s imi lar standard.

4. Fibreglass or sim ilar compos itein seco ndarystructure is acceptable.

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TY R EC O N D ITION

Methodof Testing

1. Check whetherthe tyre tread appearsto have been recut.

2. Check visually that the tyre is correctly seated on the wheel rim.

3. Exam inethe tyre for:

(a) any cut or break in the fabric.

(b) any lump or bulge.

(c) any exposure of the ply orcord structure.

4. Exam inethe valve stem for distortionor chafing.

N O T E S1. Any tyre or wheel examination must be performed with the vehicle raised on the lift to ensure that all

parts of the wheel and tyre can be examined thoroughly.

2. Examinationis confined to tyres fitted to the road wheels. If, however, any defec t on a tyre carried on aspare wheel is seen, the driver should be advised.

3. Tyres designedfor recutting or regrooving will normally be marked as regroovable.

4. The evidence of any tyre wear or damage in the full lock and full suspensionbounce conditionsshould benoted when makingthe ratings above (see also Reasonsfor Failure No. 29 page70).


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Tyre width in millimetres

Height-to-width ratio in percent. In this example,55% of 205mm .Also called the aspect ratio.

Radial constructionInner rim diameter of the tyre in inches.

Servicedescription:Load Index. Denotesthe maximumapprovedload capacityper individual tyre.

Servicedescription:Speedsymbol. Indicates the maximum speed for the tyre atfull load. In this case 241 kph (150 mph).

Productiondate code (i.e. secondweek in 2004)

Type approvalmark (ECE)designatingcountrywhere issued(E-mark). There maybe a small e instead of or in addition to the E mark. The e-m ark denotes EU

type approval. Either is acceptable.Type approval number(ECE).

Asymmetrictyre marking. Where present indicates location of tyre on vehicle.

Where present indicates direction of rotation.

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N O T E S

1. A test should not be carried out on a vehicle with a space-saving tyre fitted on any corner.

2. Any tyre or wheel examination must be performed with the vehicle raised on the lift to ensure that allparts of the wheel and tyre can be examined thoroughly.

3. Unless marked othe rwise, standard car tyres have a nominal aspect ratio of 82%. Some tyres have an

aspect ratio of 80%. These have /80 included in their size marking e.g. 165/80R1 3.Tyreswith aspect ratios of 80% and 82% are almost identicalin size and can be safely mixed in anyconfiguration on a vehicle. Wh ere this is done, Reason for Failure (1) does not apply.

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T Y R ET R E A D

Methodof Testing

Check with a tyre tread depth gauge, that the cen tral three-quar ters of the tread pattern has a depth of at least 1.6 millimetres

around the full circumferenceof the tyre.

N O T E S


2. Where the pattern is interrupted by tread wear indicators but has at least 1.6mm overall tread depth, thetyre concernedshould not be failed for inadequatetread-depth.

3. The tread pattern means the combinationof plain surfacesand groves extendingacross the breadth ofthe tread but excludes any tread wear indicatorsor features which are designedto wear out substantially

before the rest of the pattern under normal conditions of use.4. The owner should be advised of any tyre with a tread depth of less than 3mm or, where the date of

manufactureis obvious on the tyre (Item 7 on the tyre illustration in Section 37), a tyre older thansix years.


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W H E E L S

Methodof Testing

1. Make an inspection of each part of the road wheel, paying particula r attention to whether there is:

(a) any fractureo f flanges.(b) any welding breaking away.(c) any wheel badly distorted.(d) any stud hole badly worn.(e) any whee ls tud missing.(f) any wheel nut missing.(g) any wheel nut loose.(h) any wheels pokesmissingor loose.

2. Check that the correct type of whee l and wheel nut is fitted.

N O T E S


2. Where an owner refuses to allow the whee l covers of the vehicle to be removed, the vehicle should berefused a certificateon the basis that the wheel nuts have not been inspected.


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SPA R EW H E E LA N DC A R R IER(ExternalCarrierOnly)

Methodof Testing

1. Exam ine the spare wheel carrier, if fitted, for security of attachment to veh icle.

2. Exam ine the mounting points and the struc ture of the carr ier to see that they are free from fractures.

3. If the re is a spare wheel in the carrier, check that this is securely held in the carrier.

N O T E S

1. Defects in a spare wheel tyre should not be considered a reason for failure.


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B R A K EF L U ID

Methodof Testing

1. Examine the brake fluid reservo ir for fluid level, leaks and condition of fluid.

N O T E S

1. If the brake fluid cannot be easily seen without removingthe reservoir cap, then the cap must beremoved for inspection.


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C H A S S I S / U N D E R B O D Y

Methodof Testing

1. Examinemain chassis/sub-frame/underbodymembersfor deformationand/or fractures and/or advanced corrosion

(see Page 58 for criteriaon corrosion).2. Examine cross membersfor deformation and/or fractures and/or advanced corrosion.

3. Examinethe w elding and/or securingbolts/rivets for soundnessand security.

4. Examineframe/cross memberjunctionsfor indicationsof movement.

N O T E S

1. The extent of this inspection is limited to that part of the chassis/sub-frame or underbody which canreadily be seen without dismantlingany part of the vehicle.

2. Pay particular attention to a chassis or underbody which is encrusted with dirt . There may be cracks or

fracturesin h igh stress areas obscured by this dirt.3. Pay particular attention to areas around spring and running gear mountings.

4. Page 68 indicates the main chassis members of typical vehicle construction.

5. Where misalignmentis suspectedit may be necessaryto confirm that the frame/chassis is within themanufacturers tolerances.

6. Somecars (e.g. rally) may befitted with additionalnon-standardunderbody protection. If this coveringinhibits proper inspection more than the manufacturers area of cover, it is the responsib ilityo f theowner/presenter to make componentsaccessible for inspection ,otherw ise the vehicle will fail due to thelack of accessibility.


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42C H A S S I S / U N D E R B O D Y

Ma inCh as sisMem be rsare sh ow nin black.

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S T E E R I N GL I N K A G E

Methodof Testing

1. With the road wheels on the ground and the steering wheel rotated clockwis e and ant i-clockwise aga inst the road resis tance,

examine the steering mechanismfrom the point where it is secured to the chassis to the poin t where the stee ring arms aresecured to their fixings. For vehicles fitted with power steering,it may be necessaryto have the engine running.

During this inspectioncheck for:

(a) excessivewear at joints.

(b) fracture of or damage to components.

(c) insecurecomponents.

2. With steered wheels off the ground (using the vehic le manufac turers recom mendedjacking points):

(a) check for fouling of whee ls, tyres and componentsof the steering linkage with any part of the vehicle by rotating thesteering whee l through its full working range and also by examining likely fouling points for abrasion.

(b) while the steering wheel is being rotated, also check the steering column shaft and s teering box/rack for stiffness or worn

or damaged bearings.(c) note the amount of movementbetween the axle beam and the stub axle whilst each wheel in turn is rocked. Alternatively

a whee lplay detectordevice may be used.

(d) note the amount of upward movementof the stub axle, whilst each wheel in turn is lifted with a bar placed underneath it.

(e) examine visible parts of the stub axle for condition and security.

(f) where possible, examinethe king pin retainingdevice.

3. For IntegralPowerSteering;Check by the feel on the steering wheel that the power steering is operating by rocking the steering wheel with the enginerunning and the road wheels on the ground.

N O T E S

1. All steered axles are to be examined .

2. If power steering is optional on the vehicle type concerned,and is fitted to the particular vehicle but hasbeen disconnectedin such a way that it can have no adverse effect on the manual steering,this shouldnot be regarded as a defect.

3. Welding of steering parts other than by a manufactureris not acceptable.

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1 Dam agedor insecu re.

2 Splinesworn or damaged.

3 Bushes/bearingsexcess ively worn.4 Excessiveend float in pinion.

5 Obviousstiffness .

6 Steering rack gaiter, insecure, split or missing.

7 Obviousstiffnessor bearingsdamagedor worn.

8 Damaged,insecureor excessiveend float in steeringbox shaft(s).

9 Axial or radial play, worn splines or shaft twisted.

10 Dam agedor insecure.

11 Obviouslyworn or insecure.

12 Mounting obviously loose or axial or radial play.

13 Obviouslydeformed,loose or cracked.

14 3mm play (1/8) at wheel rim on 14 wheel, others pro-rata.

15 Excessivelift betweenstub axle and axle beam.

16 Dam agedor bent.

17 Absent,insecure,worn or broken.

18 Housingdamagedor worn.19 Mounting bolts missing or loose.

20 Any steeringcomponentrepairedby welding.

21 Cracks or corrosionaround attachment points.

22 Power assistance notavailableconsistentlyover full lockto lock range.

23 Missing or disconnected where powersteeringis a standardfitment by the manufactureron all veh icles of the vehicle type(make and model) on test.

24 Power steering fluid be lowminimum level.25 Fluid pipes fouling other components.

26 Leaks.

27 Worn, noisy , leak ing or drive defective.

28 Continuous oil leak from steering box/rack or steering damper.

29 Overlock ingor underlockingor fouling any other componenton the vehicle.

Note:Certain vehicles have a bui lt-in play in the steering rackmountingbushes and this should be taken into consideration.

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W H E E LB E A R I N G S

Methodof Testing

A P P L I E STO AL LROA DW H EE LS

Raise the axle(s)of the wheelsbeing examinedso that they are clear of the ground.

1. Note the movementof the wheel relative to the axle or stub axle in order to assess the play in the wheel bearings, whils t eachwheel in turn is rocked.

2. Spin each wheel rapidly and listen for any roughnessor harshnessin the bearings.

3. The vehicle should be failed if a distinctiverumble or growl is heard that indicatesthe bearing is worn or damaged.


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F R O N TS P R ING S

Methodof Testing

LeafSprings

1. Examineeach spring for its generalconditionand in particularfor fractures in the leaves, especiallyin the vicinity of theanchor eye of the main leaf.

2. Note whether any spring is so weak that it is not holding the body sufficiently far away from the wheels.

3. Exam ineconditionof spring eyes/bushes.

4. Checkthat no spring clampsare missing.

5. Check that the springs on each axle are symmetrica lly located.

6. Check that there is no movementof spring leaves denoting a fractured centre bolt.

7. Check that the attachments of the shackle/anchor brackets to the chassis are secure, looking for signs of movement of rive ts orbolts, and elongatedho les.

8. Examine the bolts and/or nuts securing the spring to the axle for tightness, and examine the spring and axle for evidence thatthese have been moving relative to each other.

CoilSprings

9. Exam ineeach spring for its generalc onditionand in particularfor fractures.


11. Examinethe attachmentof the coil springs for security.

Torsio nBa rs

12. Check torsion bars for fracture or damage.

13. Exam inethe attachmentof the torsion bars.

Sp ringPinsandBu she s

14. Examinethe amounto f play due to wear at spring anchorbrackets and pins of the spring shackles.

15. Exam inethe conditionand securityof any slipperbrackets.

16. Check that the anchor/shackle pins are fully in place, that they are secure and that locking devices are in posit ion and secure.

17. Examinethe spring mountingsfor excessiveside play.

Air and FluidSuspension

18. Check for leaks and the cond itionof the supply lines and suspensionbellows.

19. Check the conditionof levellingvalve linkages.

20. Examinethe attachment of the suspensionbellows for security.

21. Examinethe attachments for security to frame and axle.

Bond edSusp ensionUnits

22. Exam inethe bonding of the flexible elemen tto its associatedmetal fixings.23. Exam inethe conditionof the flexible elementby applying pressure.

24. Examinethe attachments for security to frame and axle.

N O T E S

1. A bush and/or pin would be considered excessively worn if wear exceeded 2mm (332) for 13mm (12)diameter pins, others pro rata.

2. Caution should be exercised in the case of springs and suspensionswith rubber/compliantmountings

where the amount of free movementin new componentsmight well exceed the above limit. In suchcases the manufacturers tolerances should be sought. Observation of the vehicle attitude whenstationarycan often reveal the effect of exhausted or broken springs, e.g. vehicle sitting down at front.

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1 Worn or exhausted .

2 Any spring leaf broken, repaired by welding or missing.

3 Spring fitted incorrectly.

4 Spring clampsm issing.

5 U-bo lts loose ormiss ing.

6 A coi l spring or torsion bar broken.

7 Obviously loose/broken.

8 Cracked or dam aged.

9 Locking device missing or insecurely fitted.

10 Worn, incorrectlypositioned,incorrecttype, or missing.

11 Obviouslyloose in the bush.

12 Worn, missing or perished.

13 Missingdamagedor broken.

14 Missing or ineffective.

15 Leaks.

16 Linkage to levellingvalve defective.

17 Valvesinsecu reor defective.

18 Suspensionbellowsgiving inadequa temovement(risk of wheel fouling).

19 P ipe damaged to the extent that it is likely to fail.20 Vehicle sitting on bump stops.

21 Failure of rubber/metalattachment.22 Deteriorationof suspensionmedium (soft and sticky).

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FR O N TSU SP EN SIO N

Methodof Testing

1. With the vehic le on the lift or pit, jack up the vehic le using the veh icle manufacturers recommendedjacking points for

checkingthe front suspension. Where this is not available, see 2, 3 and 4 below.2. For suspensionof the type show n in figure 1, jack up the front susp ensionso that the road-whe elsare clear of the groundand

the suspensionis as near as possibleto normal runningheight. Whilst each wheel is held at the top and bottom and rocked,examine for movement in the top and bottom ball joints and movementin the wishbone bushes.

3. For suspensionsof the type shown in figure 2 and 3, jack up the front suspens ionso that the road wheels are clear of theground and shake each road-wheelvigorously to determ inethe conditiono f the outer suspensionball joints and movementinthe controlarms.

4. For suspensionof the type shown in figure 4, jack up the front suspensionso that the road-wheelsare clear of the ground.Shake each wheelvigorouslyand examineeach suspensionstrut for wear at the strut sliding bush and gland as well as formovementat the strut upper support bearing and:

(a) checkfor dam age or excess ivecorrosionof the strut casing, wear in the rod and the conditionof the bonding betweenthe

meta l and flexible mater ial in the strut upper support bearing.(b) whilsteach front wheel is shaken vigorously(graspingat the 3 oclock and 9 oclock positions),check the conditionof the

outer ball joints and track control arm inner bushes for movementind icating the degree of wear.

5. For all suspensiontypes, exam ine:

(a) the cond ition of wishbonesand their inner bearings, ball joints, swivel joints, track contro l arms, anti-ro ll bars , radius rodsand their mountingbushes or washers.

(b) examineaxle beams, leading arms and swingingarm s for damage or distortion.

(c) examine the condition of the chassis frame and body shell structurein the vicinity of suspensionmountingpoints andsuspens ionsub-frame mountingpo ints for fractures, excessiveco rrosion or distortion (see page 58).


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FR O N TSU SP EN SIO N

Figure1 Figure2

Figure3 Figure4

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B R A K ELIN ES /HO SE S

Methodof Testing

Brake Pipes

1. Examineall accessiblebrake pipes to ensure that they are in serviceablecondition,free from chafingand externalcorrosionand damage.

2. Check that rigid pipes are securely held by clips or othe r means, and that rigid pipes and flexible hoses are not pos itionedinsuch a manneras to be fouled by movingparts.

3. Exam ine all flexible hoses to ensure they are not constrained in tight bends, that they have adequateroom to move asnecessarywithout fouling any other parts of the vehicle, and that they are not chafed or otherwisedamagedor perished.

4. Check whe therthere are any leaks in the system by having the brake appliedwhile examiningthe system (in the case ofveh icles fitted with a vacuum servo or power ope rated brake, the eng ine mus t be idling during this test)(2).

5. Examineflexible pipes for signs of weaknessunder pressurewith the footbrake fully applied.

6. Examinebrake pipes for repairs or unsu itablefitting .

N O T E S

1. Note: The repair or replacementof a brake pipe would requ ire a test of the pipe under pressure on the liftand a full roller brake test.

2. Provided the vacuum is maintainedin the servo, the engine may be stopped.


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1 Obviousleak.

2 Mountingbracketo r bushes missing,loose or damaged.

3 Missing or damaged.

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E L E C T R ICALSYSTEM

Methodof Testing

1. Check that the ign ition switch can be switched off.

2. Check that the ignitionkey can be removed.

3. Check for wiring that could interfere with the drivers control of the vehicle.

4. Check electrical wiring to the extent possible without dismantlingfor condition,security and position.

5. Check that any after-market item s fitted such as a m obile phone charger, radio etc. cannot be operated while the ignitionswitch is in the off position and the key removed from the switch.

6. Check (where practical)that the wiring used in after-market fitments appears suitable.

7. Check the battery for securityand leaks.


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F U E LSYST E M

Methodof Testing

1. Examinethe fuel tanks to see that they are suitable,free from advanced rust and are firmly held and secure on their

mountings. In the case of Liquid Petroleum Gas/Compressed Natural Gas, check that the fuel tank is not damaged.2. Examinefuel tank straps or supportsand mountingbrackets to see that they are secure and free from fracture and that none is

missing.

3. Exam inethe mountingbracket bolts to chassis/bodyto see that they are secure.

4. Where the LPG/CNG fuel tank is fitted inside the vehicle, check that the tank safety valve and filler valve are either pipedseparately to the outside of the vehicle or contained in a gas tight sub-compartm entwhich is vented to the outside of thevehicle.

5. Check that any ducting used for ventin gsub-co mpartme ntsor tank valves is not damagedor blocked.

6. Check that no fue l tank is fitted to the roof of the vehicle.

7. Where LPG/CNG is fitted , check that the manualhand valve on the tank can be closed off. Or where a soleno id is fitted in

place of or as an extra protectionfor the manual valve, check that it can be heard to open and close when the ignition key isswitchedon and off with the LPG/CNG switch in the on position.

8. In CNG systems, a second manual valve will norm ally be found near the filler valve which is usually in the eng inecompartment. This shouldalso be checked.

9. Check that a fue l tank cap is present and of the correct type. Check that the fuel cap seal is present and is not damaged.

10. Check that there are no leaks at all from the system in the case of petrol. In the case of diesel,check that there are no leakssuch that fuel is dripping on to the ground. In the case of LPG/CNG, check if a pressure leak (hiss ingno ise)c an be heard.

11. Examine fuel pipes to see that they are securely clipped to prevent damage by vibration, chafing or cracking.

12. Check that pipelines/hosesare not damagedor deteriorated (e.g. kinked or flattened) and are not in a position to be fouled bymov ing parts or the road surface.

13. Check that all componentsof the fuel system are securelymounted.

14. While seated in the driving position, check that the throttle control is:

(a) functionallycomplete.

(b) notcracked ,fracturedor excessivelyworn or corroded.

(c) not obstructed or impeded in its travel.

15. Check that the excess fuel device on diese l-engineveh iclescannotbe readily ope ratedfro m within the cab if it is of a typewhich, with the engine running, will cause an increase in smoke.

16. Check that the engine stop control is working satis factorily on diesel eng ine veh icles. Where LPG/CNG is fitted,check that theengine fuel supp ly solenoids(usua llyin engine compartmentfor each fuel used) can be heard to open and close when eachfuel system is selec tedon the dash swi tch.

17. Check that the air filter is present and securely fitted.

N O T E S

1. The extent of this inspectionis lim ited to those parts which can be seen and which are readily accessiblewithout dismantling.

2. All fuel tanks on the vehicle are included in the inspection.

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1 Incorrectlyor loosely mounted or damaged.

2 Advancedrust in fuel tank (see page 58).

3 Leaks.

4 Unsuitablefuel tank.

5 LPG/CNG tank fitted inside vehic le withoutb eingsub- compartmentedor without having valves piped to the outside.

6 LPG/CNG ventingor duc tingpipes dam agedor blocked.

7 Sub-compartmentobvious lynot gas tight where

valves are not piped to the outside.8 Fuel tank fitted to roof.

9 Manual or solenoid valves not operating.

10 Possib ilityof fuel lines being crushed,chafed, ruptured or subjec tto excessive vibration.

11 No fuel cap or fuel cap seal damagedor missing .

12 Sticking,binding or excessivelyworn.

13 Link pins, retaining devices or safety devices missing.

14 Crackedor fracturedmountingbracketor panel.

15 Gives off excessive smoke if operatedfrom withinthe cab after the engine has been started.

16 Not working or missing.

17 Air filter assemblyinsecure,missing or incomplete.

Note:If a veh icle is presented with a Nitrous Oxide (NO2) injectionsys tem fitted, it should be failed under Reason For Failure (4) above.

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B R A K EW H EE L U N ITS

Methodof Testing

Examineeach brake operatingwheelun it for security, leaks, corrosionor damage. By applyingthe brakes checkeach brake

operatingunit for leaks and, where possible,operation. Check that all appropria te items e.g. fixing nuts, bolts and split pins aresecure an d locked.

N O T E S

1. The vehicle wheels should be chocked during this test and the parking brake should be released.


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M E C H A N I C A LB R A K EC O M PO N EN TS

Methodof Testing

Examine the mechanical componentsof the brakes which can be seen without dismantling. Look particularlyfor:

1. Badly chafed rods or levers.

2. Frayed or seized cab les.

3. Badly damaged,corroded,seized or incorrectly fitted rods, levers or linkages.

4. Wear in rod or cable ends.

5. Wear in eyes of relay levers.

6. Wear in clevis pins, bolts, stationarypins, pivots.

7. Absenceof lockingdevices on clevis pins.

8. Excessivelyworn, contaminated,incorrectlyadjustedbrake linings or pads.

9. Fractu red,damaged,insecure,misalign edbrake drums or discs.

10. Any obstructionto free movem entin the system.

11. Any abnorma lmovem entof levers, rods or cables indicating maladjustment.

12. Securityof brake back plates or discs (includingtransmissionbrakes).

N O T E S

1. In the absence of wear indicatorsor manufacturers recommendationsregarding brake lining or disc padwear, a figure of 1.5mm (116) should be taken as a minimum thickness for bonded linings/pads and.40mm (164) above the head of the attaching rivet as a minimum thickness of riveted linings.

2. Where no faci lity is prov ided for inspectionof brake shoes/pads, item (8) above will not apply.3. The wheels shall be chockedand the park ing brake releasedw hile this test is being carried out.


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B R A K EM ASTERC Y LIND E R /SERVO /VALV E S/C O N N EC TIO N S

Methodof Testing

Master Cylind erand Rese rvo irs

1. Examinefor sec urity.

2. Checkfor leaks.

Servos

Examineservo forsecurityof mounting.

Valves

1. Exam ineall valves for security of mounting.

2. With brakes applied,check for leaks.

3. Check that load sensing/brake proportioningvalves are not damaged,leaking or inoperative and are correctly adjusted.

N O T E S

1. Visual inspection. Check for completenessand full connectionof linkage,leaks, and if possible,correctmovement. (Brakes are applied with vehicle on lift.)


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E X H A U S TSYST E M /N O IS E

Methodof Testing

1. Exam inethe conditionof the exhaustpipe and silencerfor securityand leaks.

2. Asse ssthe effectivenessof the silencerin reduc ing,as far as is reasona ble,the noise causedby the exhaus tfrom the eng ine.

3. See note below. If testing is required, the follow ing procedure mus t be followed:

N O T E S

1. If the NCT vehic le inspectordeems that the level of noise causedby the vehicle exhaustis excessive,thespecific level of noise is to be measured. The vehicle must be moved to the sound test area. The veh iclewill be requiredto have a leve l of noise less than 99dB(A)in order to pass the test.

45o 1o

Microphone

ExhaustOutlet


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R EA RSU SP EN SION

Methodof Testing

1. With the vehicle on the lift or pit, raise the rear of the vehicle so that the suspensionhangs freely using the vehicle

manufacturers recommendedjacking points for checking rear suspension.2. Exam ine axle beams, trailing arms, swinging arms, and their mounting bushes/bearings/shafts/ball joints for wear damage

and distortion.

3. Check for damage or excessive corrosion of any suspensionstrut mounting,wear in the shaft and the conditionof the bondingbetween the metal and flexible material in the strut support bear ing.

4. For all suspensiontypes examine the condition of wishbones, ba ll joints, track control arms, anti-roll bars, transverse rods,radius rods and their mountingbushes,bearings,shafts,washersor retainingdevices.

5. Examinethe conditionof the chassis frame and body shell structure in the vicinity of suspensionmountingpoints andsuspensionsubframemounting pointsfor fractures ,excessive corrosionand distortion.


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R E A RS P R IN G S

Methodof Testing

LeafSprings

1. Examineeach spring for its generalconditionand in particularfor fractures in the leaves, especiallyin the vicinity of theanchor eye of the main leaf.


3. Examineconditionof spring eyes and bush es.

4. Checkthat no spring clampsare missing.

5. Check that the springs on each axle are symmetrica lly located.

6. Check that there is no movementof spring leaves denoting a fractured centre bolt.

7. Check that the attachments of the shackle/anchor brackets to the chassis are secure, looking for signs of movement of rive ts orbolts, and elongatedho les.

8. Examine the bolts and/or nuts securing the spring to the axle for tightness, and examine the spring and axle for evidence thatthese have been moving relative to each other.

CoilSprings

9. Exam ineeach spring for its generalc onditionand in particularfor fractures.


11. Examinethe attachmentof the coil springs for security.

Torsio nBa r

12. Check torsion bars/bushesfor fracture or damage.

13. Exam inethe attachment of torsion bars.

Sp ringPinsandBu she s

14. Examinethe amounto f play due to wear at spring anchorbrackets and pins of the spring shackles.

15. Exam inethe conditionand securityof any slipperbrackets.

16. Check that anchor/shackle pins are fully in place, that they are secure and that locking devices are in position and secure.

17. Examinethe spring mountingsfor excessiveside play.

Air and FluidSuspension

18. Check for leaks

Nct Manual 2010

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