Navigating MOT Inspection Manual Changes

Understanding the Evolving MOT Inspection Manual

The Driver and Vehicle Standards Agency (DVSA), formerly VOSA, regularly updates its procedures and guidelines to ensure road safety standards are maintained. One of the most crucial documents for any MOT testing station is the MOT Inspection Manual. This comprehensive guide details the procedures and criteria for testing vehicles. Recent significant changes have been implemented, consolidating previous manuals and introducing new methods of inspection (MOI) and reasons for failure (RfR). This article aims to demystify these changes, providing clarity on what they mean for testers and vehicle owners alike, focusing on Classes 3, 4, and 7 vehicles, with considerations for Class 5.

Consolidation and Key Changes

A notable shift has been the integration of the Class 5 Inspection Manual with the existing Class 3, 4, and 7 manual. This consolidation streamlines the process and ensures consistency across different vehicle classes. Furthermore, VOSA has taken this opportunity to update, add, or remove specific MOIs and RfRs, reflecting advancements in vehicle technology and a refined understanding of safety critical components.

Abbreviations and Definitions

The initial sections of the manual, including abbreviations and definitions, have seen several additions. New terms like 'Abandon', 'Abort', 'Bus', 'Large Class 4 vehicle (DGW over 2500kg)', 'Minibus', 'Ministry Plate', and 'Siemens' have been incorporated to cover a broader range of vehicles and testing scenarios.

Introduction and Accessibility

A significant procedural change in the introduction section states: "No need to jack up the rear of a class 4 vehicle with a DGW exceeding 5000kg (eg large motorhomes)". This aligns the testing procedure for these heavier vehicles with that of Class 5 vehicles, simplifying the process and reducing potential complications.

The 'How to use this manual' section has been updated to address situations where vehicle loading might impede access to testable items. The updated text now reads: "If, because the vehicle is loaded or a bonnet, door etc, cannot be opened or has been significantly reduced in size, you cannot gain access to a testable item, which was originally accessible only through a bonnet, door, access panel, etc., you must refuse to carry out the test or fail the vehicle." This clarifies the procedure when access is obstructed.

Interestingly, a paragraph on page 9 regarding the transfer of test information to the VTS Device via an NTs Smart Card has been removed. This reflects VOSA's decision to abandon plans for direct data storage from emission, headlamp, and brake tests onto smart cards, likely due to evolving digital transmission methods.

Special Notices (SNs) and Manual Updates

The handling of Special Notices (SNs) has also been clarified. The manual now states that replacement pages containing amendments or additions must be retained and acted upon. A printed copy of SNs must be filed and readily retrievable, with the recommendation to copy relevant items into the main manual. SNs will be produced electronically via the VTS Device, and the electronic version of the Manual will be updated automatically. While Appendix A was previously required for signing off manual amendments, it is no longer mandated.

Key Testing Area Modifications

Lighting, Signalling and Visibility

Several changes impact the testing of vehicle lighting:

• Position Lamps, Headlamps, Registration Plate Lamps, and Rear Fog Lamps: The requirement for testers to tap these lamps to check for flickering has been removed. Specifically, RfR 1.1, 'flickers when tapped by hand', is no longer an MOI or RfR.
• Stop Lamps: Now located in section 1.2, a note clarifies that while the precise position of stop lamps isn't part of the inspection, testers should visually confirm they are at similar heights and distances from the vehicle's sides.
• Rear Fog Lamps: Moved to section 1.3, the updated notes require 50% of the lamp to be working and visible from the rear. The tapping procedure for flickering has also been removed.
• Direction Indicators: In section 1.4, advisory notes now include specific guidance for vehicles first used before 1 September 1965, allowing direction indicators to be incorporated with stop, side, or rear lamps, with white front and red rear indicators permitted. The criteria for 50% working and 50% visible, along with the precise location of lamps, are now specified.
• Reflectors: Section 1.5 now states that the precise location of reflectors is not part of the test, provided they are roughly symmetrical in height and distance from the vehicle's side, and 50% is visible. The note regarding reflectors being rendered inoperative by paint has been deleted, with failures now falling under 'obscurity'.

Audible Warning Device

The horn testing procedure, now in section 1.6, includes an additional MOI to check for the presence and security of the horn control, which was not previously explicit. A corresponding RfR has also been added.

Headlamps

The headlamp section (now 1.7) includes a new information note: "Care must be taken to ensure that relatively large front lamps on old vehicles are headlamps and not merely position lamps." The MOI and RfR for the precise position of headlamps have been standardised with other lamps and reflectors. A specific information note for Class 3 vehicles requiring only one headlamp has been removed.

Headlamp Aim

While the manual's description of headlamp aim hasn't changed significantly, the RfRs have. The previous RfR allowing failure for a headlamp beam image significantly affected by damage or deterioration has been removed. This presents testers with a choice: either fail the aim for being too high, low, left, or right, or log the item under 'items not tested' if the pattern is indiscernible due to damage, making it impossible to assess the aim.

Steering System

The 'Lock to Lock' check in section 2.2 has been revised. The MOI now includes two steps: first, assessing for tightness or roughness while turning from lock to lock with wheels on turning plates, and second, turning the wheels from lock to lock with wheels on unlocked turning plates. This standardises the procedure for checking steering system roughness, which was previously less defined.

Power Steering

Section 2.3 on power steering incorporates new information for vehicles with manually switched park assist systems, clarifies leaks from power steering systems versus other sources, and introduces a new RfR for excessive free play between the ball pin and the ram. The wording for 'power steering pipes chafing' has been changed to 'pipes fouling other parts of the vehicle'. Extensive MOI additions cover checks for ram anchorage security, ram body integrity, and free play at the anchorage point. The RfRs have also been updated to include issues like evidence of power steering removal, cracked or damaged ram bodies, and excessive free play at the ram anchorage.

Suspension

Several modifications have been made to the suspension sections:

• Suspension General (2.4): A note clarifies that RfR 1.a (cracked or fractured spring leaves) also applies to curled leaves preventing disengagement from a slipper. An additional MOI requires checking the condition of the slipper and rebound pin, with a corresponding RfR for excessively worn, cracked, or insecure slippers, or missing rebound pins. The check for cracks, fractures, distortion, corrosion, wear, and insecurity of members has been expanded to explicitly include MacPherson Strut casings and sub-frames. Additional RfRs for suspension components include missing items, cracked, fractured, insecure, distorted, corroded, or inadequately repaired members.
• Front Suspension (2.5): An MOI reminder has been added to check the Vehicle Specific Information (VSI) for jacking positions. For kingpin/bush wear, while precise limits aren't defined, a guide suggests that for a 50cm wheel, movement should not exceed 10mm when rocked with the wheel braked.
• Rear Hub Bearings (2.6): Class 5 and large Class 4 vehicles (over 5000kg DGW) should not be jacked at the rear to inspect hub bearings.

Braking System

Significant updates have been made to the braking system sections:

• Hand Operated Control Valves (3.2): A note reminds testers that some pneumatic components may experience a degree of leakage. Corrosion is now a RfR for brake rods, levers, or linkages. Testers are warned not to remove reservoir caps on high-pressure servo boost systems.
• Hub Components (3.5): The RfR for brake discs or drums has been reworded to focus on conditions that 'seriously weaken or insecure' them. Advisories for worn, scored, or pitted discs have been removed and will now need to be added as manual advisories.
• Brake Pipes (3.6): The most significant change concerns brake pipe clips. A missing clip is no longer an automatic failure if the pipe remains adequately supported, a notable relaxation. Certain alloy components may exhibit white surface deposits that are not considered excessive corrosion. New formats for checking hydraulic and air systems, along with a section on Additional Braking Devices (e.g., retarders, exhaust brakes), have been introduced, with minor additional RfRs for air systems concerning cracks or fractures to cylinders or actuators.
• Brake Performance (3.7): The measurement of out-of-balance on steered axles has been updated. The MOI now specifies noting the out-of-balance across each steered axle as the service brake is gradually applied. The RfR for brake imbalance has been adjusted: a 25% imbalance (30% for Class 5) is now applicable only during brake application, not release. Brake release is assessed by how evenly the braking effort decreases. Notes regarding Electronic Parking Brakes, prop-shaft parking brakes, and gradient brake tests for specific large vehicles have been added. Decelerometer testing should not be performed on vehicles with damaged or significantly underinflated tyres, nor should retarders be used during these tests.
• Brake Efficiency Calculations (3.8, 3.10): New pages detail brake efficiency calculations for Class 5 vehicles and provide revised, clearer information on ministry plates.

Tyres

Section 4.1 on tyres has introduced additional RfRs concerning tyres of different types or structures fitted to steerable or driven axles. This ensures consistency when vehicles have multiple steerable or driven axles. New information notes cover ministry plates on pre-1982 Class 5 vehicles, testing twin rear wheel setups, and vehicles with shrouded wheels.

Conclusion

The MOT Inspection Manual is a dynamic document, constantly evolving to reflect the realities of modern vehicle testing. Testers must stay abreast of these changes to ensure compliance and maintain the highest standards of road safety. The consolidation of manuals and the refinement of MOIs and RfRs aim to create a more consistent and effective testing process. Understanding these updates, particularly those concerning lighting, steering, suspension, brakes, and tyres, is paramount for all professionals involved in the MOT testing regime.

Frequently Asked Questions

Q1: Do I need to print the MOT inspection manual?
While the manual is updated electronically, it is advisable to retain printed copies of Special Notices and relevant amendments for easy reference and to ensure you are working with the most current guidelines.

Q2: What was the MOT Special Notice about the reminder service?
An old Special Notice covered the MOT reminder service, which ended in August 2014, and the removal of 'items not tested' from the manual. The current rules are in the updated MOT inspection manual for Classes 3, 4, 5, and 7.

Q3: Is Appendix A still required for MOT test changes?
No, Appendix A is no longer required for signing off manual amendments as per the recent updates.

Q4: What are the main changes to headlamp aim testing?
The RfR that allowed failing a headlamp due to damage significantly affecting the beam image has been removed. Testers must now assess if the aim is too high, low, left, or right, or if the pattern is indiscernible, in which case it may be logged as 'items not tested'.

Q5: How has the testing of brake pipe clips changed?
A missing brake pipe clip is no longer an automatic failure if the brake pipe remains adequately supported, indicating a relaxation in this specific requirement.

If you want to read more articles similar to Navigating MOT Inspection Manual Changes, you can visit the Automotive category.