Vehicle and Operator Services Agency The MOT Inspection Manual Private Passenger and Light Commercial Vehicle Testing Preface This Manual sets out the testing procedures and standards for those who carry out statutory testing of cars, private buses and light commercial vehicles. Vehicle owners may also find the Manual useful because it details the inspection to which vehicles are subjected and the reasons why an MOT test certificate could be refused. This Manual was based on the domestic regulations in force at the time of publication and complies with Annex II to Directive 2009/40/EC as amended by Commission Directive 2010/48/EU. Future changes in the law, or in vehicle or equipment design may result in variations to the test requirements. General information regarding documentation and the responsibilities of those involved in testing are contained in the Vehicle and Operator Services Agency MOT Testing Guide. The M.O.T. Inspection Manual Issue Date: April 2013 Written by the Vehicle and Operator Services Agency © Crown copyright. Published by Atos on behalf of the Vehicle & Operator Services Agency – to whom applications to reproduce material should be made in writing c/o Procurement Unit, Berkeley House, Croydon Street, Bristol, BS5 0DA. First Edition crown copyright 1992 Fifth consolidated edition 2002 Second Edition crown copyright 2004 Third Edition crown copyright 2010 Fourth Edition crown copyright 2011 ISBN 978-0-9549352-5-2 The M.O.T. Inspection Manual Issue Date: April 2013 Contents Page i Introduction Abbreviations and Definitions Section 3 Brakes Introduction 3.1 Parking Brake Control How to Use this Manual 3.2 Hand Operated Brake Control Valves Recommended Inspection Routine 3.3 Service Brake Control Anti-Lock Braking and Electronic Stability Control 3.4 Systems Section 1 Lamps, Reflectors and Electrical Equipment 3.5 Mechanical Brake Components 1.1 Front and Rear Position Lamps, End Outline Marker Lamps, Registration Plate Lamps 3.6 Braking Systems and Additional Braking Devices 1.2 Stop Lamps 3.7 Brake Performance 1.3 Rear Fog Lamps 3.8 Method of Calculating Brake Performance 1.4 Direction Indicators and Hazard Warning Lamps 3.9 Example of Manufacturers Plate 1.5 Rear Reflectors 3.10 Brake Efficiency Table 1.6 Audible Warning (Horn) 1.7 Headlamps Section 4 Tyres and Road Wheels 1.8 Headlamp Aim 4.1 Tyres 1.9 Electrical Wiring and Battery 4.2 Road Wheels Section 2 Steering and Suspension Section 5 Seat Belts & Supplementary Restraint Systems (SRS) 2.1 Steering Control 5.1 Seat Belt Requirements 2.2 Steering System 5.2 Seat Belt Condition 2.3 Power Steering 5.3 Seat Belt Installation Check (Class 4A & 5A only) 2.4 Suspension – General 5.4 Supplementary Restraint Systems (SRS) 2.5 Front Suspension, Wheel Bearings and Drive Shafts 2.6 Rear Suspension and Wheel Bearings 2.7 Shock Absorbers 2.8 Suspension Type Diagrams The M.O.T. Inspection Manual Issue Date: April 2013 Contents Page ii Section 6 Body, Structure and General Items Section 9 Motor Tricycles and Quadricycles 6.1 Vehicle Structure, Body and General Items 9.1 Lighting 6.2 Seats and Doors 9.2 Motorcycle Derived Steering / Suspension 6.3 Registration Plates and Vehicle Identification Number 9.3 Brakes 6.4 Load Security, Spare Wheel and Carrier 9.4 Tyres and Road Wheels 6.5 Speed Limiter 9.5 Seat Belts 6.6 Towbars 9.6 Body and Structure 6.7 Speedometer 9.7 Exhaust, Fuel and Emissions 6.8 Driving Controls (Class 5 only) 9.8 Drivers View of the Road 6.9 Glazing (Class 5 only) Appendices Section 7 Exhaust, Fuel and Emissions A Reserved For Future Use 7.1 Exhaust System B Reserved For Future Use 7.2 Fuel System C Structural Integrity and Corrosion 7.3 Exhaust Emissions-Spark Ignition D Tyre Size, Ply Rating and Load Index Tables 7.4 Exhaust Emissions-Compression Ignition Section 8 Drivers View of the Road 8.1 View to Rear 8.2 Wipers and Washers 8.3 Windscreen 8.4 Bonnet The M.O.T. Inspection Manual Issue Date: 01 January 2012 Introduction Page i Section Contents Item Subject Item Subject Abbreviations and Definitions How to Use This Manual Introduction 1. The Manual 1. Application (Classes 3, 4, 5 & 7) 2. Page Layout 2. Refusal to Test a) Information Columns 3. Inspection Procedure b) Method of Inspection Columns 4. Narrow Track Vehicles c) Reasons for Rejection Columns 5. Retest Following Failure d) Notes 6. Recording Defects 3. Vehicle ‘first used’ Dates – Application of Test Criteria a) Reasons for Rejection 4. Assessment of Component Wear and Deterioration b) Dangerous Defects 5. Modified Vehicles c) Other Defects 6. Inappropriate Repair or Modification 7. Testing Personnel 7. Use of Equipment 8. Vehicle Specific Information (VSI) 8. Use of an Assistant 9. The MOT Testing Guide 9. Disabled Driver’s Controls 10. Special Notices (SNs) and Manual Replacement Pages 10. The VTS Device User Guide Recommended Topside Inspection Routine 11. Road Testing Recommended Underside Inspection Routine 12. Health and Safety The M.O.T. Inspection Manual Issue Date: April 2013 Abbreviations and Definitions Introduction – page 1 Abandon The term used when a test cannot be completed because the NT considers it unsafe to continue or because it becomes apparent during the test that certain items cannot be satisfactorily inspected. An appropriate fee may be charged for the test. Abort The term used when a test cannot be completed because of a problem with the VTS’s/DC’s testing equipment or the NT. No fee may be charged for the test. AE Authorised Examiner - the organisation that operates and manages one or more VTSs and is responsible for controlling the quality of testing carried out. Except in the case of a ‘sole trader’ the AE is not a person but a legal entity (e.g. a company or partnership). ATL Automated Test Lane - These are lanes authorised by VOSA for use in the automated mode. Bodied A bodied vehicle is defined as ‘a vehicle with a structure consisting/comprising of a floor pan and panels which, with a roof fully encloses the vehicles vehicle occupants and without a roof encloses them other than where the roof would be’. As a guide, if the driver sits in the vehicle with surrounding structure it would be classed as bodied. Bus A motor vehicle which is constructed or adapted to carry more than eight seated passengers (see also Minibus). Catch Up The process by which testing test data recorded while testing under Emergency Testing is subsequently entered via the VTS Device. Coach A motor vehicle which is constructed or adapted to carry more than 16 seated passengers, with a DGW of more than 7,500kg and a maximum speed in excess of 60mph. DGW Design Gross Weight - i.e. the maximum gross weight that the vehicle was designed to operate at by the manufacturer. This is normally found on the manufacturer’s plate fixed to the vehicle, or in the case of older or heavier vehicles by a `Ministry Plate’. Such plates are not required on all vehicles. ET Emergency Testing, the process by which testing may continue when the computerised system is not available due to a wide scale failure affecting a significant number of VTSs. Fallback The process by which testing may continue when the computerised system is not available at a VTS, for example, following the breakdown of the VTS Device. Fallback The process by which test data recorded while testing under Fallback is subsequently confirmed on the MOT computer database. Review Immediately Taking place without delay. Large Class 4 A Class 4 vehicle with a DGW greater than 2500kg. MAM Maximum Authorised Mass – The maximum gross weight permissible in GB. Minibus A motor vehicle constructed or adapted to carry more than eight but no more than sixteen seated passengers (see also Bus). Ministry Plate Displays the maximum authorised weights at which a vehicle may be operated. This information supersedes the maximum weights displayed on the Manufacturer’s plate. MoI Method of Inspection. The M.O.T. Inspection Manual Issue Date 01 January 2012 Abbreviations and Definitions Introduction – page 2 NT Nominated Tester - a person nominated by an AE to carry out tests, Inspectors appointed by Designated Councils to carry out tests, all of which are approved by VOSA. Also VOSA staff appointed under section 66A of the Road Traffic Act 1988. OPTL One Person Test Lane. These are lanes authorised by VOSA to conduct testing where the tester has the option of not using an assistant if so desired. Password Personal Identification, used in conjunction with a Smart Card to access the MOT database via the VTS device. Can be numbers or letters, or a combination of both. QC Quality Control. RfR Reason for Rejection. Replacement Replacement pages are normally sent out under a Special Notice. They must be inserted into the manual immediately. Superseded pages should be manual pages removed. Siemens Siemens IT Solutions and Services Ltd – Service provider for MOT Computerisation. Smart Card A card issued to an authorised user to access the MOT database via the VTS Device. SN Special Notice - an official notice issued from time to time by VOSA to inform AEs, NTs and other system users of changes to the testing scheme. SNs may also be used to highlight areas of concern and to advise of developments of the scheme. ULW Unladen Weight - The weight of a vehicle inclusive of the body and all parts which are ordinarily used with the vehicle when working on a road. Unladen weight does not include the weight of water or fuel used for the propulsion of the vehicle, or of loose tools and loose equipment. VOSA The Vehicle and Operator Services Agency. VSI Vehicle Specific Information, provided to NTs to aid the correct assessment of a vehicle under test. VT20 An MOT Test Certificate which includes the English/Welsh dual language version (VT20W). VT20 ET An MOT Test Certificate for issue during a period of Emergency Testing. VT30 A notice of refusal of a MOT Test Certificate including the Welsh counterpart (VT30W). VT32 An Advisory Notice – issued to advise of items of concern identified during the test that do not justify the refusal of a test certificate. VT40 MOT Inspection Check List used by a NT during a test for vehicles other than motor bicycles (see VT40M). VT40M Motor bicycle MOT Inspection Check List used by a NT during a test. VTS Vehicle Test Station. VTS Device The Computer device installed at each VTS on which each test must be registered, from which MOT documentation is produced and to perform certain administrative functions. V5/V5C Vehicle log book/registration certificate. Issued by the Driver and Vehicle Licensing Agency. The M.O.T. Inspection Manual Issue Date 01 January 2012 Introduction Introduction – page 3 1. Application (Classes 3, 4, 5 & 7) paragraph 1 continued This Manual is a detailed guide to the inspection for statutory MOT testing Table to Determine the Vehicle Class and Test Requirements for of the following Classes: Tricycles and Quadricycles Class 3 3 wheeled vehicles not more than 450kg unladen weight Vehicle type Description Tested in (excluding motor bicycles with side cars). Class Class 4 Cars, including 3 wheeled vehicles more than 450kg unladen Three wheeled vehicle with max speed of weight, Taxis, Minibuses and Ambulances up to 12 passenger Moped 45km/h, not over 50cc for a petrol engine seats, Goods Vehicles not exceeding 3000kg Design Gross or 4KW for any other engine or electric 3 Weight (DGW), Motor Caravans and Dual Purpose Vehicles. motor, not more than 450kg ULW Three wheeled vehicle with wheels Class 5 Private passenger vehicles, Ambulances, Motor Caravans and Motor symmetrically arranged, a max speed over 3 Dual Purpose Vehicles with 13 or more passenger seats. Tricycle 45km/h, or engine size over 50cc, not Class 7 Goods Vehicles over 3000kg up to and including 3500kg more than 450kg ULW (DGW). If a vehicle is presented with a manufacturer’s plate Three wheeled vehicle with wheels and a ‘Ministry plate’ the weights to be used are those on the Motor symmetrically arranged with a max speed 4 ‘Ministry plate’. Tricycle over 45km/h, or engine size over 50cc, more than 450kg ULW More detailed definitions are given in the MOT Testing Guide. Light Four wheeled vehicle with a max ULW of Note: To determine the seating capacity of a passenger vehicle, the Quadricycle 350kg, max speed of 45km/h and not over number of occupied wheelchairs that can be carried should be added to the (classed as 50cc for a petrol engine or 4KW for any 4 number of seats. a moped) other engine or electric motor. Four wheeled vehicle with a max ULW of Tricycles and Quadricycles are tested under Classes 3 or 4 and these Quadricycle 400kg (550kg for a goods vehicle) with a 4 vehicles can present particular problems at MOT test. max net power of 15KW Section 9 of this Manual provides additional information for testing these If any of the above vehicles are electrically powered, their unladen weight vehicle types. However, sub-section 9.2 should be used in place of must not include the weight of the batteries. Sections 2.1 and 2.2 for vehicles with motorcycle derived steering and/or suspension components fitted. If there is doubt about the power output or the weight of the vehicle, the presenter must provide documentary evidence. Other than for the inspection of tyres, any two wheels of a vehicle shall be regarded as one wheel if the distance between the centres of the areas of contact between such wheels and the road surface is less than 460 mm. Note: A tester should be aware that this may affect the test Class, e.g. a three wheeled vehicle with a wheel layout meeting these criteria must be tested as a motor bicycle. Cont’d The M.O.T. Inspection Manual Issue Date: 01 January 2012 Introduction Introduction – page 4 2. Refusal to Test paragraph 2 continued This Manual does not include the reasons for refusing to test a vehicle in e. The VTS asks for the fee to be paid in advance and this is not done. the Reasons for Rejection columns. VTSs may only test those Classes and f. The vehicle emits substantial quantities of avoidable smoke. types of vehicle that they are authorised to test and which are of a size and weight that can be accommodated by the authorised equipment. g. A proper examination cannot be carried out because any door, tailgate, boot, engine cover, fuel cap or other device designed to be readily opened If any of the following reasons apply, the test should not be carried out, the cannot be readily opened. vehicle presenter informed and any fee paid for the test must be returned. It is therefore advised that ‘refusal’ items are checked before starting the h. The condition of the vehicle is such that, in the opinion of the NT, a proper test. examination would involve a danger of injury to any person or damage to the vehicle or other property. If the vehicle presenter requires written confirmation of why the test cannot be carried out, the test should be registered using the VTS Device. A VT30 i. The vehicle has neither registration mark nor VIN/Chassis No./Frame No. should be issued clearly showing the reason(s) why the test could not be by which it can be identified, or that all such identifications are illegible or carried out. use letters and numbers not normally used in the English language. If reason to refuse ‘i’ applies, issue a hand written VT30 containing as In addition to this an NT must decline to test any vehicle that is not of a many of the vehicle details as possible. A copy of the VT30 should be Class they are authorised to test or it is of such a size, weight or retained by the VTS. configuration it cannot be properly or safely tested on the approved facilities. The reasons for refusing to carry out the test are: Note: For narrow track vehicles see item 4. a. The log book / registration certificate or other evidence of the date of first use is not produced if the information therein, is necessary for the test to be If despite due care initially, it becomes apparent during a test that the test carried out. cannot be completed for any of the above reasons, you must fail the vehicle because the test could not be satisfactorily completed. Note: Normally this evidence is only necessary if the vehicle has a ‘cherished’ registration mark or if the registration mark’s year letter does Any re-examination and fee must be in line with normal policy (see Fees not make clear the standard that should be applied - for instance, regarding and Appeals Poster) treating the component which could not be examined Hazard Warning Device requirements for vehicles first used on or after 1 as a failure item. April 1986. b. The vehicle or any part or equipment on the vehicle is so dirty that examination is unreasonably difficult. c. The vehicle is not fit to be driven when necessary to complete the test because of a lack of fuel, or oil, or for any other reason. d. The NT considers insecurity of a load or other items would prevent a proper test being carried out - unless the load is secured or removed. Cont’d The M.O.T. Inspection Manual Issue Date: 01 January 2012 Introduction Introduction – page 5 3. Inspection Procedure paragraph 3 continued Each vehicle must be registered for test by the NT at the commencement Once the inspection is completed, the NT must record the test results using of the test. This will normally be done via the VTS Device. When testing in the VTS Device, or by contacting the Atos Service Desk when testing in Fallback, (see MOT Testing Guide) this must be done by contacting the Fallback. The only exception to this is when testing using ET procedures. Atos Service Desk. The only exception to this is when testing using ET Brake efforts achieved during a test should be recorded and entered on the procedures. VTS Device after the completion of the test as follows: The NT who registered the vehicle for test must personally carry out the  Roller and plate brake tests- record the brake effort of each wheel test, without avoidable distraction or interruption. Using a suitable assistant tested and whether ‘lock-up’ occurs. Note also the maximum out-of- where necessary. balance across each axle. The VTS Device will calculate the required The diagrams on pages 11 and 12 show typical inspection routines which results for service and parking brake efficiency as well as the out of will aid the tester in making a thorough inspection of a vehicle. These balance result if required. routines may need to be varied to suit different test bay layouts and  Decelerometer tests - record the efficiencies recorded by the meter. equipment types.  Gradient tests - record the result (Pass or Fail). For example, at some testing stations, where the roller brake tester is positioned in advance of the pit or lift, it might be more convenient to During Fallback the NT must, calculate the efficiencies, supply appropriate conduct the brake performance test before inspecting the rest of the values requested by the Atos Service Desk, and retain the readings for later vehicle. data entry or confirmation. This practice is permissible, but it must be noted that a tester should not If testing under ET, the brake efficiency of each system must be calculated by proceed with the brake performance test if there is a defect with the vehicle the NT and the readings retained for later data entry. which could cause; See the MOT Testing Guide for a full explanation of the procedures to be  injury to any person; adopted during Fallback and ET.  or damage to the vehicle or other property. If testing under ET the results, which are recorded under normal test conditions, should be recorded on the VT40 and any printout retained. It is advisable to examine, as far as possible, all of the vehicle before carrying out a brake performance test. There is no requirement to jack the rear wheels of any vehicle in: Testers are reminded to take care when jacking up vehicles in order to  Class 4 (where the DGW exceeds 5000Kg) avoid causing damage, and may wish to refer to manufacturers’ information or, if available.  Class 5. Particular care is also needed when jacking vehicles fitted with pneumatic, hydraulic or self levelling suspension. Cont’d The M.O.T. Inspection Manual Issue Date: April 2013