Reference handbook: Ontario's passenger/light-duty vehicle inspection standard

7/25/2019 Reference handbook: Ontario's passenger/light-duty vehicle inspection standard

1/96

Passenger / Light-Duty Vehicle Inspection Standard

Reference Handbook

October 2015

The information contained in this document is confidential and proprietary to the Government of Ontario. Unauthorizeddistribution or use of this document or the information contained herein is strictly prohibited.


2/96

Copyright and Disclaimer

Government of Ontario reserves the right to make changes in the information containedin this publication without prior notice. The reader should in all cases consult the Ministry

of Transportation to determine whether any such changes have been made.

Queens Printer for Ontario, 2015

Other product or brand names are trademarks or registered trademarks of theirrespective holders. This document contains proprietary and confidential informationabout Government of Ontario. Disclosure or reproduction is prohibited without priorexpress written permission.


3/96

Introduction

As partners in road safety, licensed Motor Vehicle Inspection Station owners andtechnicians must carefully review and apply the requirements contained in thistechnical Passenger / Light Duty Vehicle Inspection Standard (herein after referred

to as the Standard). This Standard is intended to apply to light-duty trucks andpassenger vehicles requiring the issuance of a Safety Standards Certificate (SSC)for the purposes of vehicle registration and/or transfer of ownership. The purpose ofthe inspection is to ensure that the vehicle meets a minimum safety standard at thetime of inspection. A determination must be made as to whether the condition of thevehicle at the time of the inspection conforms to the requirements outlined in thisReference Handbook.

This Standard replaces Schedules 1 and 2 of Ontario Regulation 611. ThoseSchedules previously contained the standards applicable to SSC inspections.

All items listed in this Standard must be inspected in accordance with the specific

procedures outlined. An SSC is a legal declaration that the vehicle was inspected inaccordance with the legislation, Regulation 611, and this Standard and met all ofthe requirements at the time of the inspection.

Should you have any questions related to the requirements contained in thisStandard, please refer to the Ministry of Transportation website:

Ontario.ca/MVIS

Ontario.ca/CIVA
http://www.mto.gov.on.ca/english/trucks/motor-vehicle-inspection-stations.shtmlhttp://www.mto.gov.on.ca/english/trucks/motor-vehicle-inspection-stations.shtmlhttp://www.mto.gov.on.ca/french/trucks/motor-vehicle-inspection-stations.shtmlhttp://www.mto.gov.on.ca/french/trucks/motor-vehicle-inspection-stations.shtmlhttp://www.mto.gov.on.ca/french/trucks/motor-vehicle-inspection-stations.shtmlhttp://www.mto.gov.on.ca/english/trucks/motor-vehicle-inspection-stations.shtml


4/96

Table of Contents

UPDATED PASSENGER / LIGHT-DUTY VEHICLE INSPECTION STANDARD .. 1Reference Handbook ..................................................................................................... 1

1. INSTRUCTIONS FOR TECHNICIAN / INSPECTOR CONDUCTINGINSPECTIONS ............................................................................................................... 51.1. Inspection Methods ................................................................................................... 51.2. Inspection Outcome Based on Current Vehicle Condition .................................. 51.3. Inspection Report ...................................................................................................... 51.4. Workplace Safety ...................................................................................................... 61.5. Informational Notes ................................................................................................... 6

2. TERMINOLOGY ......................................................................................................... 62.1. Application .................................................................................................................. 62.2. Definitions ................................................................................................................... 62.3. Categorization of Fluid (Liquid) Leaks ..................................................................... 82.4. Illustrations and Diagrams Used in the Standard .................................................. 92.5. Measurements and Tolerances .............................................................................. 92.6. Identification of Defective Conditions of the Types of Hose, Tubing and Lines

Used on Vehicles ................................................................................................... 11

SECTION 1 POWERTRAIN........................................................................................................................ 12

SECTION 2 SUSPENSION......................................................................................................................... 23

SECTION 3 BRAKE SYSTEMS.............................................................................................................. 28

SECTION 4 STEERING................................................................................................................................. 43

SECTION 5 INSTRUMENTS AND AUXILIARY EQUIPMENT........................................ 49

SECTION 6 LAMPS.......................................................................................................................................... 52

SECTION 7 ELECTRICAL SYSTEM................................................................................................... 65

SECTION 8 BODY............................................................................................................................................. 67

SECTION 9 TIRE AND WHEEL.............................................................................................................. 82

SECTION 10 COUPLING DEVICES.................................................................................................... 88

SECTION 11 ROAD TEST........................................................................................................................... 92


5/96

1. Instructions for Technician / Inspector ConductingInspections

1.1. Inspection Methods

The inspection of vehicle components and systems conducted to determinecompliance with this Standard consists mainly of visual inspection activities inSections 1-10 and through the completion of an on-road evaluation, details ofwhich are found in Section 11.

An inspection will also involve testing, removal and/or disassembly ofcomponents, measurements and other actions in certain cases. Whenever anitem requires more than a visual inspection, additional procedures are specificallyprovided. These are displayed with the heading Additional InspectionProcedure(s): appearing before the text describing the necessary steps.

1.2. Inspection Outcome Based on Current Vehicle Condition

A pass or fail outcome of a vehicle inspection is based on the condition of thevehicle at the time of the inspection. The determination does not involve aprediction about a vehicles condition in the future.

1.3. Inspection Report

For each SSC inspection, the inspecting technician must complete an inspectionreport. This report must be provided to the customer and retained in accordancewith Ontario Regulation 601.

The following items are noted in the Standard as recordable items and must beincluded on the inspection report.

Tell-Tales indicating a fault

Fuel Tank Level

Tire Tread Depth

Tire Inflation Pressure (Initial and final) if corrected by more than 5psi

Disc Brakes- Rotor Thickness- Pad (Friction) Material Thickness of Inner and Outer Brake Pad

Brake Drum System- Brake Shoe Lining Thickness- Brake Drum Diameter

Passenger / Light-Duty Vehicle Inspection Standard Page 5 of 96

Note: All inspection procedures are visual unless additional inspection procedures are indicated. Conditions shownin this mannerare defined conditions. The definitionscan be found in the introduction section.


6/96

Additional details on the type of information that must be recorded can be foundin the respective sections contained in the Standard and in the Regulation.

1.4. Workplace Safety

Some of the inspection procedures described in this Standard require the use oftools and equipment, and may involve safety hazards. It is assumed that theindividual performing inspections according to this Standard is fully familiar with allrelevant workplace safety requirements and protocols.

No specific safety warnings are provided within this document. All relevant andappropriate safety precautions are the responsibility of the inspector / mechanic /technician and the workplace where the inspection is conducted.

1.5. Informational Notes

In many cases, additional information is provided to clarify the inspectionprocedure or assist in consistent interpretation of the Standard. These aredisplayed with the heading Note: appearing before the text.

2. Terminology

2.1. Application

Various terms and acronyms are used throughout this Standard. These termshave specific and consistent meanings as they relate to conducting safetyinspections and identifying defective conditions. The purpose of defining theseterms is to support consistent interpretation and application of the language usedhere. The terms that are defined below are highlighted whenever they appear ineach section to remind the reader that the condition is one of those that isspecifically defined. This reminder also appears in the footer of each page of thisdocument.

2.2. Definitions

The meaning of each of the terms, for the purposes of conducting inspectionsaccording to this Standard, is as follows:

abnormally worn means unusual, excessive or exceptional wear of avehicle component indicative of the presence of some deterioration or defect inthat component, or in a related part of a vehicle. It is acknowledged that for many




7/96

components and systems some level of wear is normal and does not have anyeffect on vehicle safety. It is expected that the technician knows the amount andtype of wear that is (normal based on the age and operation of a vehicle.

ANSI means standards developed by the American National StandardsInstitute (ANSI).

broken means burst, cracked, crushed or damaged.

CCMTA means Canadian Council of Motor Transport Administrators(CCMTA)

CMVSS means Canada Motor Vehicle Safety Standards (CMVSS) and theirsupporting Technical Standards Documents. These are Canadian safetystandards for vehicles that were developed and are updated by TransportCanada.

crazed a network of fine cracks in the surface

damaged means any unintended condition, or condition caused by meansother than normal use, that is likely to impair normal function.

FMVSS means Federal Motor Vehicle Safety Standards. These are UnitedStates safety standards for vehicles that were developed and are updated by theNational Highway Traffic Safety Administration of the Department of Transport.

industry standard means installation, modification or repair methodsdescribed in industry-accepted standards or recommended practices publishedby Mitchell Repair Information Company, ALLDATA, the Society of AutomotiveEngineers (SAE), I-CAR, Canadian Standards Association (CSA) and othersimilar documents from similar organizations.

inoperative means a vehicle component or system that does not operate theway it normally operates or the vehicle manufacturer intended it to operate.

insecure means (a) a component is becoming detached due to deteriorationof the means of attachment, or (b) the means of attachment is unable towithstand normal vehicle operation or is not at least equivalent to the OEMstandard means of attachment.

loose means that an item is detached, or no longer fully attached, due toimproper installation, failure or deterioration of one or more means of attachment.

missing means that an item is absent (such as removed or detached) thatis ordinarily present on the vehicle, was present on the vehicle when the vehiclewas manufactured, or is required for normal and safe vehicle operation.




8/96

manufacturer means the manufacturer of the vehicle, the manufacturer of amajor vehicle component or system, or manufacturer of aftermarket parts that aredirect replacements for OEM parts.

OEM means original equipment manufacturer and refers to the brandname manufacturer of the vehicle.

OEM standard means the manufacturing methods, component andassembly quality levels, and performance levels set by the manufacturer of avehicle or vehicle component to ensure a vehicle is able to perform safely asintended. It includes component quality, performance levels, repair methods,durability, safety and the service methods outlined in the warranty and serviceliterature provided for the use and maintenance of a vehicle. Parts supplied byOEM, and established aftermarket manufacturers of parts intended for directreplacement of OEM parts, are generally considered to meet OEM standard

operate as intended means the manner in which a vehicle component or

system ordinarily operates, operated when the vehicle was manufactured, or isrequired to operate for normal and safe vehicle operation

reject if means a condition if present at the time of inspection or after repairsthat results in a failed inspection.

tell-tale means an optical signal that, when alight, indicates the activation ordeactivation of a device, its correct or defective functioning or condition, or itsfailure to function.

2.3. Categorization of Fluid (Liquid) Leaks

Every reference to a fluid (or liquid) leak listed as a reject condition is categorizedwith respect to the level of severity of the leak: either level 1, level 2 or level 3.Each category is defined below. A vehicle with a leak that meets the definedlevel, or leaking more severely than this level, will cause the vehicle to failinspection.

level 1 leak means seepage of fluid that is not great enough to form drops.

level 2 leak means seepage of fluid that is great enough to form drops, but

not great enough to cause the drops to fall during inspection.

level 3 leak means seepage of fluid that forms drops that fall duringinspection




9/96

2.4. Illustrations and Diagrams Used in the Standard

In an effort to improve the consistency and uniformity of the inspection process, aseries of diagrams and illustrations is used in this version of the Standard. Whena diagram or illustration is in conflict with a legislated or regulatory requirement,

the latter prevails.

2.5. Measurements and Tolerances

Many of the inspection items and reject conditions involve measurements ofmass or weight, pressure and distance. To achieve consistent application of eachcriterion that involves such a measurement, it is necessary to address the degreeof precision associated with such measurements. In determining the appropriatelevel of precision or tolerance, it is also necessary to consider the measuring toolsthat will be commonly used to make each of these measurements.

The level of precision associated with any measurement is defined by thetolerance stipulated for it. Tolerance is expressed as a plus or minus (+/-) value.The actual window of precision is double the value of the tolerance. For example,50 mm (+/- 1 mm), means a value of 49 to 51 mm. The measurement toleranceof 1 mm renders a measurement precision of within 2 mm.

Given the similarities in the measurements that appear most frequently in thishandbook, standard tolerances are given for most of these measurements. Thestandard tolerances that are listed below apply in all cases where noadditional tolerance is provided. In cases where the standard tolerancedoes not apply, the tolerance for that cri terion is provided adjacent to the

measurement.Whenever a tolerance is provided adjacent to a measurement,the tolerance stipulated with the measurement is to be used in place of thestandard tolerance listed below.

Measurements of distance are the most common in this Standard, and also havea significant variance in terms of the range of distance that is used. Four differentstandard tolerance values are used for distance.

PressureMetric (SI) pressure value = kilopascals (kPa),Imperial (American) pressure value = pounds per square inch orpounds/inch

2(psi)

Conversion Factors: 1 kPa = 0.145 psi, 6.9 kPa = 1 psiStandard tolerance for all pressure values: +/- 5 kPa (0.5 psi)

DistanceMetric (SI) distance value:millimetre (mm)Imperial (American) distance value: inch (in.)Conversion Factors: 1 mm = 0.039 in., 1 in. = 25.4 mmStandard tolerance for distance value ranges




10/96

Tolerances for distance measurements vary based on the type andprecision of the criterion as follows:

1. Large distance measurements of greater than 25 mm: tolerance is+/- 5 mm (accuracy is to the nearest 10 mm)

2. Short distance measurements of1 to 25 mm, where the distancevalue is expressed as a whole mm: tolerance is +/- 0.5 mm(accuracy is to the nearest 1 mm)

3. Precise short distance measurementsof1.0 to 25.0 mm, wherethe distance value is expressed as one-tenth of a mm:tolerance is+/- 0.05 mm (accuracy is to the nearest 0.1 mm)

4. Micro distance measurementsof less than 1 mm: tolerance is +/-0.005 mm (accuracy is to the nearest 0.01 mm)

For the purpose of these tolerances, the following equivalent values

are used: Comparable Measurement Tolerances

Tolerance in metricmeasurements

Tolerance in imperialmeasurements

5 mm 0.125 (1/8) in.

0.5 mm 0.02 in.

0.05 mm 0.002 in.

0.005 mm 0.0005 in.

Metric / Imperial Conversions

25.4 mm = 1.0 in.10.0 mm = 0.394 in.

0.0254 mm = 0.001 in.




11/96

2.6. Identif ication of Defective Conditions of the Types of Hose,Tubing and Lines Used on Vehicles

Diagram Characteristics Defective Condition

Type 1 Copper, steel or plastictubing used for liquid or vapour.Made of a single layer of material.

Wear or damage isvisible on theoutside.

Type 2 Plastic (usually nylon)tubing commonly used in air-brake systems.Uses no reinforcement ply. Innercore and outer cover are usuallydifferent colour.

Inner core becomesvisible from theoutside, as shownby colour change.

Type 3 - Plastic (usually nylon)tubing commonly used in air-brake systems.Uses reinforcement ply. Inner andouter core are different colour.(Note: Type 2 and 3 may appearidentical externally.)

Reinforcement plyor inner core isvisible from theoutside, as shownby colour change.

Type 4 Stainless steel braided(or otherwise) outer cover withinner layer of tubing.

Wear or damagevisible on the outercover.

Type 5 Synthetic rubber hosewith inner reinforcement ply.

Wear or damageexposing thereinforcement ply.

Type 6 Synthetic rubber hosewith multiple reinforcement plies.

Wear or damageexposing the outerreinforcement ply.

Type 7 Flexible hose with oneor more reinforcement plies thatmay be fabric or steel, and anouter protective layer.

Wear or damagethrough the outerprotective layer andouter cover,exposing areinforcement ply.




12/96

Section 1 Powertrain


1. Accelerator Pedal / Throttle Actuator

Item and Method of Inspection: Reject if:

Additional Inspection Procedure(s):With engine running, press and releasethe accelerator pedal. Check engineresponse.

a) pedal / actuator a)- binding, inoperative, missing,or

engine fails to respond normally

b) anti-slip feature b)

- ineffective,looseormissing

c) mount c)- deteriorated or weakened by corrosion,

orinsecure

d) linkage / cable d)- binding,brokenorinsecure- deficient part is used that is notOEM

standard- throttle cable is binding, frayedorseized

e) springs e)-broken,corroded, deteriorated,

missing,stretched or improper type

2. Exhaust System


Additional Inspection Procedure(s):Inspect with engine running.

Note:Minor leaking and resulting soot tracksare normal at joints in exhaust systems.

Updated Passenger / Light Duty Vehicle Inspection Standard Page 12 of 96



13/96



a) manifold a)-broken,cracked, leaking,looseor

missing

b) muffler

Note:TheOEMmuffler or one that meets theOEM standardis required on everyvehicle.

b)- cracked, perforated or leaking- bypassed, disabled,missingor

removed- deficient part is used that does not

meetOEM standard- patched in any manner that is not

consistent withindustry standard

c) resonator, catalytic converter and

particulate trap

c)

- cracked, perforated or leaking- patched in any manner that is not


d) exhaust pipe d)- cracked, collapsed or pinched,missing,

perforated or leaking- patched in any manner that is not


e) mounting hardware e)

-broken, insecure,looseormissing- deficient part is used that does not

meetOEM standard

f) location / heat damage

Note:

Heat damage can sometimes be due tothe absence of a heat shield originallyprovided by themanufacturer.

f)- exhaust-system component is located

so as to cause charring or other heatdamage to any wiring, fuel line, brakeline or combustible material of thevehicle

- any exhaust component passes

through an occupant compartment

g) turbocharger g)- leaking exhaust gases- level 3 leakof oil or coolant

h) exhaust-pipe termination h)- exhaust gases are expelled into




14/96



Note:Also applies to the exhaust system ofany auxiliary equipment (for example,

generators, auxiliary heaters).

Occupant compartment includes any partof the vehicle which has openingsconnecting it to any part of the vehiclewhich may be occupied.

occupant compartment- exhaust gases are expelled within the

perimeter of the cab and / or sleeper

- exhaust system shortened or modifiedfrom original equipment so as to fail todirect the exhaust beyond theunderbody of the occupantcompartment or luggage compartment

- the distance between the outlet andperiphery of the underbody, past whichit directs the exhaust, exceeds 15 cm

i) diesel exhaust fluid (DEF) system

Additional Inspection Procedure(s):

Visually inspect system usingOEMservice information as a guide.

i)- storage tank is damagedorinsecure

- level 2 leakat any location in the DEFsystem- storage tank filler cap ismissing

3. Drive Shaft, Differential


Additional Inspection Procedure(s):Inspect using hand pressure and suitabletools

a) U-joint / CV joint

Note:

Weather checking / cracking ispermissible on boot as long as there isno crack that exposes internal jointcomponents or lubricant to externalcontamination.

a)- rotational free play is present- jointis noisy (for example, clicking)

during road test and (i) rotation ofwheel binding or (ii) steering movementadversely affected

- protectiveboot isloose, missing,opencrack or torn

- lubricantis leaking from CV joint

b) attaching hardware b)- loose, missingor stripped

c) centre bearing and mount c)- damaged,loose, missingorabnormally

worn- insecuremounting or mount is




15/96



abnormally deteriorated

d) slip joint d)

- radial wear at joint exceedsmanufacturerspecification

e) hanger bracket and hardware, andmetal guard or catch

e)-missing, loose,cracked- mounted in a manner that fails to

prevent drive shaft from falling toground

f) differential


Test the functioning of the differential onlywhen there is evidence of a problem.Refer tomanufacturerserviceinstructions, and confirm that thedifferential is functioning properly.

f)

- there is evidence that differential is not

functioning as intended (affectsdriveability)

4. Clutch and Clutch Pedal


Additional Inspection Procedure(s):Inspect clutch operation and adjustmentaccording tomanufacturerserviceinstructions.

a) operation a)- fails to operate in the manner

prescribed by themanufacturer

b) adjustment b)- is not adjusted according to

manufacturerinstructions

c) pedal c)-broken,cracked,loose,ormissing- welded or repaired in a way that does

not meetindustry standard- deteriorated or weakened by corrosion,

orinsecure




16/96



- anti-slip feature is ineffective,looseormissing

d) clutch pedal hydraulic system d)- fluid reservoir is belowmanufacturersminimum level or level 2 leakof fluid atany point

5. Engine / Transmission Mount


a) condition / attachment a)- bent,looseormissing

- a bolt or insulator ismissing- an insulator isbroken,deteriorated ,

level 2 leak,or swollen abnormally- a mount or part of a mount is replaced

with a product or material that is notequivalent toOEM standard

6. Engine Shutdown


Additional Inspection Procedure(s):Test operation according tomanufacturerservice instructions.

a) ignition switch a)- engine fails to shut down when ignition

switch is turned off

b) mechanical shutdown b)- engine fails to shut down when device

is actuated

c) remote or emergency shutdown device c)- fails tooperate as intended




17/96


7. Engine Start Safety Feature



Test operation to confirm engine start isprevented according tomanufacturerservice instructions.

a) ignition interlock operation

Note:This includes the neutral safety switch onvehicles, except buses, with anautomatic transmission with a GVWR of4536 kg or less and includes the clutch

pedal safety switch for vehicles, exceptbuses, with a GVWR of 4536 kg or lessand manufactured during or after June2005.

a)- fails to prevent engine start-up as

intended

8. Gear Shifter / Selector and Position Indicator


a) location a)- cannot be viewed by a person seated

in driver position

b) operation b)- gear shifter / selector movement is stiff

or does not enable all gear positions tobe freely engaged or selected

- indicator fails to indicate selected gearon a vehicle equipped with anautomatic transmission

c) automatic transmission - shift patternillustration (label, embossment, etc.) -or selector

c)- illegible, not clearly visible to driver or

missing- inaccurate display of shift position- engine starts other than in P or N




18/96


9. Engine or Accessory Drive Belt


Note:

This section applies only to a drive beltdirectly connected to the engine.

A drive belt that is not required for safeoperation of the vehicle (for example,

A/C) may bemissingif it doesnt affectthe operation of required vehiclefunctions.

a) condition a)-broken,frayed, oil-contaminated or

missing- crack exceedsOEM standardor

industry standard

b) adjustment / tension

Additional Inspection Procedure(s):Check the tension of drive belt(s).

Note:Normal belt tension should be consistentwithOEM standardorindustry standard.

b)- belt is slipping

c) drive belt pulley c)- bent,broken,cracked or out of

alignment

10. Electric or Hybrid-Electric Powertrain System


Note:

All electric drivetrain components that canbe accessed without removing othercomponents, covers or panels must bevisually inspected.

a) electrical system connections a)- connector is damagedor corroded in a

way that exposes any conductor- connector is damagedorinsecure,




19/96



- connector is unable to properlyconnect or lock into place

b) wiring b)- corroded or damagedin a way thatexposes any conductor

- insulation is chafing due to abrasivecontact with any vehicle part

- conduits are incomplete and not ingood condition

c) drive motor / generator c)- damaged,insecureorloose- indication of burning or overheating

- drive component excessively worn

d) self-diagnostic indicator

Additional Inspection Procedure(s):Visually inspect the system indicator(s)usingOEMservice information as aguide.

d)- there is any condition indicated by the

system that is defined by theOEMasbeing unsafe

11. Gasoline or Diesel Fuel System


a) fuel system a)- level 1 leakor spillage of fuel present

from any part of the fuel system

b) filler cap b)- improper type ormissing

c) tank, filler neck / tube and vent tube

Note:

Fuel tank level must be recorded onInspection Report

c)- cracked, perforated,insecuremounting

or weld isbroken

- improper tank (not intended for thestorage of automotive fuel)

- improper vent- improper repair

d) tank mount and strap d)-broken,cracked,looseormissing




20/96



- deficient part is used that does notmeetOEM standard

- fastener islooseormissing

e) line, hose, fitting and connection

Note:Refer to correct type of hose or tube andthe related defective condition(s) asdefined in the chart in the definitionsection of this standard.

e)- chafed, cracked orinsecure- deficient product is used that does not

meetOEM standardnot approved foruse in a fuel system

- any section of a line, hose or tube isworn or damaged

f) fuel pump f)- damagedorinsecure

12. Pressurized or Liquefied Fuel System (LPG, CNG and LNG)


Note:In Ontario, pressurized fuel systems areinspected according to the requirementsof the TechnicalStandards and Safety

Act, and are administered by the TSSA(Technical Standards and Safety

Authority). The inspection items beloware intended as a general safetyinspection of the fuel system and do notreplace the inspection requirements ofTSSA.

If you smell propane or natural gas orsee anything of concern in the LPG orCNG installation, please contact anauthorized repair facility.

a) TSSA Compliance Decals- 2 decalsrequired for CNG- converted vehicles

and 3 decals required for LPG-converted vehicles.

Note:LPG-converted vehicles require decalthat indicates the vehicle is incompliance with the B149.5 that expires

a)

- decal is not displayed- an incorrect decal is affixed to vehicle- information on decal is not readable- window label is expired




21/96



every 5 years.

Window label (LPG only):

Permanent label near door latch or theinside of the glove compartment forpropane and CNG:

- labelmissingor expired

Propane and NG diamond required: Apropane-fuelled highway vehicle shall beidentified by a weather-resistant,diamond-shaped label affixed to its

exterior vertical, or near vertical, lower-right rear surface, but not to its bumper.

b) filler cap b)- improper type ormissing

c) tank and cylinder c)- crack or other damage to tank or

cylinder- improper repair

d) tank mount and retainer strap d)-broken,cracked,looseormissing




22/96




e) line, hose, fitting and connection e)

- chafing, cracked orinsecure- any section of a line, hose or tube isworn or damaged


f) fuel pump, or other fuel systemcomponent

f)- damagedorinsecure

g) leakage g)- evidence of any fuel leak




23/96

Section 2 Suspension


1. Suspension and Frame Attachments


Note:This sectionapplies to all types ofsuspension.

Manufacturerwelding of components is anormal part of many manufacturingprocesses, and is distinct from welding tomodify or repair a part.

Additional Inspection Procedure(s):Raise the vehicle as necessary to accessthe suspension components.

a) vehicle ride height

Additional Inspection Procedure(s):Check ride height while vehicle isunloaded, parked on a flat level surfaceand with tires inflated to specifiedpressure. The allowable variation in ride

height from left to right is based on aground-to-vehicle measurement.

a)- one side of the vehicle is more than 25

mm, higher or lower than the otherwhen measured at the tire centerline

b) frame bracket, mounting bracket andhanger

b)-broken,cracked, damaged,loose,or

missing- perforated due to corrosion or

deterioration- welded or repaired in a way that does

not meetOEM standard

c) mounting fasteners c)

-broken,cracked,looseormissing

d) tire interference d)- the condition of the suspension system

allows a tire to contact any part of thevehicle frame or body




24/96



e) suspension travel e)- there is no or very limited suspension

travel due to a binding or seized

suspension component, or due toimproper stiffness or specification ofsuspension (which is either topped orbottomed out)

2. Axle Attaching and Tracking Components


Note:This sectionapplies to all types of

suspension.

a) axle attachment, axle saddle a)- bent,broken,cracked,looseormissing- axle has shifted from its normal position

b) bushing (rubber or composite material) b)-missing, looseor shifted out of place- wear or damage permits suspension

component to shift out of position

c) arm, rod, strut / shock suspension,control arm c)- bent,broken,cracked,loose, missing,or worn out

- perforated due to corrosion ordeterioration

- welded or repaired in a way that doesnot meetOEM standard

- wear or damage permits axle or wheelto shift out of position or requiredorientation

- binding strut bearings/mounts prevent

free rotation of steering wheel

d) stabilizer / anti-sway bar, ball and socketor link

d)- bent,broken, missing- welded or repaired in a way that does





25/96


3. Spring and Spring Attachment


a) leaf spring a)

- any spring leaf isbroken, missing,worn more than 3 mm, cracked orshifted out of place

- any spring leaf is worn more than 3 mmin the hanger contact area or whereleaves are in contact with each other

- leaf is shifted and contacting anothervehicle part

b) composite spring

Note:

Some change in the appearance of acomposite spring, described as fuzzing /frayed is normal as the spring ages.

b)- worn more than 3 mm in load bearing

area-broken,crack of any length visible onboth sides of a spring, splintered,delaminating or not the same type oneach side of vehicle

c) shackle, pin, bushing c)-broken, missing, looseor pin seized- shifted out of normal position- fastenerlooseormissing- vertical movement of a spring or

shackle against a spring pin exceedsOEM standardor if not available; wearexceeds limit below

- for pin size up to 25 mm, wear limit is2.0 mm

- for pin size greater than 25 mm, wearlimit is 3.0 mm

d) U-bolt and hardware (centre bolt,fasteners, saddles or shackles)

d)-missing, looseor shifted out of normal

position- welded or repaired in a way that does


e) spring contact area of hanger (slipper)

Note:Wear plates are permitted by somemanufacturersin the spring contact

e)- repaired by welding (except installation

of wear plates)- spring-load bearing area is worn more

than 3 mm




26/96



(slipper) area of fabricated hangers.

f) coil spring f)-brokenor shifted out of normal position- spacer is fitted between coils

g) torsion bar g)-broken,cracked ormissing- repaired by welding

h) rubber load cushion h)- rubber block or vertical pin isbroken,

loose, missingor split

4. Air Suspension


Additional Inspection Procedure(s):Check with air system at normaloperating pressure

a) ride height a)- height is above or belowOEM

specification- vehicle leans to one side

b) air spring (air bag) b)- improperly seated, cracked, cut,

patched or reinforcing ply is exposed- audible air leak

c) air spring base, mounting plate c)-broken, missing,or cracked- perforated by corrosion or deterioration- welded or repaired in a way that does


d) air system

Additional Inspection Procedure(s):Inspect the function and operation of theair- suspension system and controls inaccordance withmanufacturerserviceinstructions.

d)- compressor does not function as

intended- pressure control, pressure regulator or

gauge ismissingorinoperative




27/96



e) air line, connection and fitting

Note:

Refer to correct type of hose or tube andthe related defective condition(s) asdefined in the chart in the definitionsection of this standard.

e)- fitting, repair method, installation or

modification does not meetOEM

standard- an inner layer is exposed due to

abrasion or rubbing- fitting or connection isbroken,cracked,

flattened or leaking- air flow through a line is restricted due

to melting, flattening, deformation orkinking

f) height control valve f)- inoperative

- a system originally equipped with 2valves has a valvemissingor has beenconverted to a single valve

- a system with only one valve has thevalve positioned in a location other thannear the center of an axle

5. Strut / Shock Absorber


Additional Inspection Procedure(s):Check shock absorbers by rapidlylowering and raising the vehicle.

a) operation a)- vehicle oscillates more than two cycles

after release

b) condition b)- damaged, disconnected ormissing

c) mount and hardware c)- broken, loose,binding ormissing




28/96

Section 3 Brake Systems



Inspecting Internal Brake Components

1. Disassembly of Wheels and Drums for Inspection

Internal brake components must be inspected at every inspection. Disassembly orremoval of wheels, and/or brake parts, is required to facilitate full inspection of allcomponents.

2. Required Measurement of Brake Components

Brake inspections require certain components to be measured. These measurementsare required to be recorded on the inspection report. The items that must be measuredfor each type of brake are as follows:

2.1 Drum Brake Systems

For drum brakes, the brake-shoe lining thickness and brake-drum diameter must bemeasured at every inspection.

2.2 Disc Brake Systems

For disc brakes, the rotor thickness and pad friction material thickness of the innerand outer brake pad must be measured and recorded at every inspection.

Friction-material thickness can be determined by measuring the friction material itself, orby measuring the combined thickness of the friction material and pad backing plate, thendeducting the thickness of the backing plate. Always record the thickness of the frictionmaterial only.




29/96


Note: The performance of the service brake system is tested as part of the Road Test(Section 11).

1. General


a) brake system a) A component of the brake system ismissing or has been disabled

2. Hydraulic System Components


a) metal line and fittings


Inspect lines and fittings for leaks whilebrakes are applied with a heavy force onthe brake pedal similar to what would beused in an emergency stop. Operateengine if necessary to maintain power-assist.

Note:Surface rust and corrosion is normal onmetal lines and fittings, and is not causefor rejection.

a)- heavy rust, corrosion or scaling is

present on any metal line or fitting thatreduces or increases the thickness orcompromises the structural integrity ofthe material

- level 1 leak- chafing, cracked, flattened or restricting

section- insecuremounting causing line to shift

out of its normal position- repaired by welding or soldering- repaired using material or method that

does not meetOEM standard- Connections between brake systemcomponents are not a flared type fitting,or does not meetOEM standard

- Component does not meetOEMstandard

b) flexibleline / hose

Additional Inspection Procedure(s):Inspect flexible hoses while brakes areapplied with a heavy force on the brake

pedal similar to what would be used in anemergency stop. Operate engine ifnecessary to maintain power-assist.

b)- bulged or swells under pressure,

flattened, twisted, restricting section orinsecuremounting

- outer composite material is cracked orchafed exposing an inner layer asshown in hose and tube condition chartin introduction or located so as to rubagainst any component.

- Component does not meetOEMstandard




30/96



c) master cylinder


Apply moderate foot force on the brakepedal for 10 seconds to check for pedalmovement.

Apply heavy foot force to the service brakepedal to check for total pedal travel ( in thecase of power boosted brakes, with theengine running)

c)- damagedorinsecuremounting- fluid is contaminated

- level 1 leak- fluid level is below indicated minimum

level or, if not indicated, more than 13mm from top

- filler cap is damaged,looseormissing,vent holes are plugged or gasket ismissingor swollen

- pushrod incorrectly adjusted- with moderate foot force maintained on

the service brake for 10 seconds thepedal moves towards the fully applied

position (engine must be running forpower boosted brake systems).

- with heavy foot force applied to theservice brake pedal and, in the case ofpower boosted brakes, with the enginerunning:

the total pedal travel exceeds 80 percent of the total available travel, and

on the vehicle equipped with dual-circuit hydraulic brakes, the brake-

failure warning lamp illuminates- brakes do not release, preventing the

vehicle from rolling, upon removal offorce from the brake pedal

d) differential pressure switch d)- switch or electrical connection is

damaged,insecureorloose- level 1 leak- inoperative

e) variable or proportioning systemAdditional Inspection Procedure(s):

Check links for mechanical defects. Testthe functioning of the proportioning valveonly when there is evidence of aproblem. Refer tomanufacturerserviceinstructions and confirm that the valve is

e)- link is damaged,missing,or seized- level 1 leak- proportioning valvemissing, inoperative

or bypassed




31/96



functioning properly.

f) auxiliary or work brake (line-lock device)

Note:Line-lock devices block brake fluid fromreturning to the master cylinder as ameans of holding a vehicle stationary.Improperly installed they can interferewith normal service brake operation.

f)- any device is installed that interferes with

normal service brake operation

3. Brake Pedal / Actuator


a) pedal a)-broken,cracked,loose,ormissing- welded or repaired in a way that does


b) mount b)- deteriorated or weakened by corrosion

orinsecure

c) anti-slip, high-friction feature on pedalapplication surface (for example, rubber

cover)

c)- ineffective, deteriorated,loose or

missing

4. Vacuum Assist (Boost) System


a) line, hose and clamp a)-broken,chafed, collapsed, cracked,

leaking,looseormissing- insecuremounting, incorrect type or

positioned within 40 mm of any exhaust

system component

b) check valve b)- incorrectly installed orinoperative,

leaking ormissing

c) tank c)- damaged, structurally deteriorated from




32/96



corrosion,insecureorloose,leaking ormissing

d) operation

Additional Inspection Procedure(s):Test system operation as describedbelow.

Stage 1 Start engine, build to fullvacuum, shut engine off, make 2 fullbrake applications.

Stage 2 With engine off, press brakepedal several more times to eliminateremaining vacuum. Apply a light force to

the brake pedal and start the engine.

d)- during stage 1 - vacuum reserve is

insufficient to assist two full brakeapplications

- during stage 2 - downward movementof brake pedal is not felt when engine isstarted

e) vacuum pump

Additional Inspection Procedure(s):Confirm proper operation of the vacuumpump tomanufacturerspecifications.When no specification is available, checkwith engine running at 1200 rpm usingvehicle gauge, or connect external gauge.

e)- vacuum pump does not operate within

manufacturerspecifications, or when nospecification is available, is unable toachieve and maintain a vacuumbetween 4 kPa and 5 kPa

5. Hydraulic Assist (Boost) System


a) engine-driven pump, reservoir and belt

Additional Inspection Procedure(s):Check with engine stopped and withengine running.

Inspect drive belt according to Section 1.Power Train, Item 9. Engine or AccessoryDrive Belt.

a)- level 2 leak- fluid level is below indicated minimum

level or, if not indicated, more than 25mm from top

- filler cap is damaged,looseormissing

b) line and hose

Additional Inspection Procedure(s):Check with engine stopped and withengine running.

b)- level 2 leak-broken,chafed, collapsed, cracked,

looseormissing- insecuremounting or incorrect type

c) operation c)




33/96



Additional Inspection Procedure(s):Confirm proper operation of the hydraulicassist (boost) system according to

manufacturerservice instructions.When nomanufacturerserviceinstructions are available, check asdescribed below.

Test Method 1 - For a system withelectrically driven back-up pump. Operatebrakes with engine running and enginestopped with ignition off. Observe systemoperation and status of indicator lamps.

Test Method 2 For a system with gas-

accumulator back-up. Stop engine anddeplete pressure reserve. Then apply alight force on brake pedal and startengine.

- hydraulic assist (boost) is not availableor system malfunctions

- system does not operate as described

inmanufacturerservice instructions-tell-talelamp is activated, showing asystem malfunction

- during Test Method 1 - system does notoperate as described inmanufacturerservice instructions

- during Test Method 2 - on a systemwith gas-accumulator back-up - pedalfails to sink down and then push backup again

6. Air Assist (Boost) System


a) operation


Confirm proper operation of the air assist(boost) system according tomanufacturerservice instructions.

When nomanufacturerservice instructionsare available, check as follows: Stopengine and deplete pressure reserve. Thenapply a light force on brake pedal and startengine.

a)- system does not operate as described

inmanufacturerservice instructions- downward movement of brake pedal is

not felt when engine is started

7. Brake System Indicator Lamps


a) operation

Additional Inspection Procedure(s):Confirm the location and labeling of brakeindicator lamps according to

a)-missing,not red or amber in colour- does not operateaccording to

manufacturerservice instructions




34/96



manufacturerservice instructions.

Check operation of braketell-taleaccording tomanufacturerservice

instructions.

When nomanufacturerserviceinstructions are available, begin withengine stopped, and then turn ignition on.Lamps must turn on when ignition is firstturned on. Lamps may go out after 2 3seconds or may stay on until the engineis started.

Note:Sometell-talesmay stay on, after a repair

or system malfunction, until vehicle speedreaches 8 - 16 km/h.

- indicates a brake system malfunction ordefect

8. Drum Brake System Components


Additional Inspection Procedure(s):Inspection requires removal of the drumand also other components as necessaryto inspect all components as detailed

below.

a) brake-shoe lining condition a)- lining material isbroken,contaminated

or cracked- signs of rust-jacking (friction material

lifting due to rust build-up, shoe-tabledeformation, friction material separatingfrom backing material)

- lining protrudes outside of drum- lininglooseor separating from shoe

- shim is used between lining and shoe- shoe or lining is installed incorrectly(such as primary and secondary shoesreversed)

b) brake-shoe lining thickness

Additional Inspection Procedure(s):Lining thickness must be measured at

b)- bonded brake-shoe lining thickness is

less than 1.6 mm, where the lining is




35/96



each inspection, and the measurementmust be recorded on the inspectionreport.

Note:Lining thickness measurements are takenabove a rivet or shoe at the most wornlocation.

thinnest- riveted brake-shoe lining thickness is

less than 1.6 mm above rivet

1.6 mm = 2/32 in.

c) brake drum condition

Note:Heat checks and some surface cracks onthe friction surface are normal.

Heat checking is identified by a number ofshort, fine, hairline cracks on the brakingsurface.

c)- crack, groove or worn area is deeper

than the drum wear limit- surface cracks or heat checks extend

completely across the brake surface.- any external crack is present

- friction surface isabnormally worn

d) brake drum diameter (wear)

Additional Inspection Procedure(s):Brake drum diameter must be measuredand recorded on the inspection report.See Introduction to Section 3 for details.

Note:

Drum diameter measurements must betaken using a suitable tool and with thelevel of accuracy defined by themeasurement tolerance but never with alevel of accuracy less than 0.05 mm

d)- measured drum diameter exceeds limit

indicated on the brake drum or, if notavailable,OEM standardorindustrystandard

e) self-adjuster mechanism e)-broken,incorrect thread direction,

inoperative, missingor seized

f) anchor pin / bracket and return spring f)-abnormally worn,bent,broken, looseor

missing- spring stretched

g) backing plate g)- bent, damagedorloose- shoe contact area is grooved or worn in

a manner that restricts free movement




36/96



of shoes

h) axle and spindle h)- cracked or damaged

i) wheel cylinder i)- inoperativeor seized, damaged,loose

orinsecuremounting- level 1 leak- dust seal is cracked or split,missing,

damagedor deteriorated

j) wheel seal j)- level 2 leak

9. Disc Brake System Components


Additional Inspection Procedure(s):When an inspection reveals evidence of adefect or abnormal condition, brakecomponents must be disassembled to thepoint necessary to verify defect.

Refer to the instructions in the

Introduction to Section 3 to determinewhat measurements are required to betaken and recorded.

a) disc (rotor) condition

Note:Lateral run-out and parallelism needs tobe checked only where there is evidenceof a problem (for example, severe brakepedal pulsation upon brake application).

Heat checks and some surface cracks onthe friction surface are normal.

Heat checks are identified by a number ofshort, fine hairline cracks on the brakingsurface.

a)-broken,pitted, damagedor cracks on

surface extending to the outer edge;broken/ cracked cooling fins; ormechanical damage that may beattributable to abnormal wear on frictionsurfaces

- any surface crack, groove or worn areais deeper than the wear limit

- crack extends from the friction surfacethrough to the cooling vent

- contact pattern of the pad on solid rotormaterial (not rusted) is less than 75% ofthe radial width around the entire rotor,on one side




37/96



- lateral run-out or parallelismmeasurement exceedsOEMorindustrystandard.

b) disc (rotor) thickness

Additional Inspection Procedure(s):Rotor (disc) thickness must be measuredand recorded on the inspection report.

Note:Measurements must be taken using asuitable tool with the level of accuracydefined by the measurement tolerance,but never with a level of accuracy less

than 0.05 mm.

b)- thickness between friction surfaces at

any point on the pad-contact surfaces isless than the minimum indicated on thebrake rotor,OEM standardorindustrystandard

c) caliper

Note:If the dust cover ismissingordeteriorated, it is acceptable, as long asthe condition does not present a potentialsafety hazard.

c)- assembly seized or binding, mounted

incorrectly or inferior attaching bolt isused

- slide pin / slider or pad slider is seizedor binding, damagedorabnormallyworn

- caliper guide is welded or repaired in away that does not meetOEM standard

- level 1 leak- pad retainer is bent, damaged,insecure

ormissing- boot or bellows is cracked or

deteriorated, damagedormissing- piston seized or binding

d) anchor plate d)- looseor bolt ismissing

e) pad condition e)- damaged, contaminated,broken,

cracked orabnormally worn- friction materialloose or separating on

pad, or pad installed incorrectly- signs of rust-jacking, (friction material

lifting due to rust build-up or frictionmaterial separating from backingmaterial)




38/96



f) pad (friction material) thickness

Additional Inspection Procedure(s):Pad (friction material) thickness of bothinboard and outboard pad must bemeasured and must be recorded on theinspection report.

Note:Pad (friction material) thickness can bedetermined by measuring the frictionmaterial itself or by measuring thecombined thickness of the frictionmaterial and pad backing plate, thendeducting the thickness of the backing

plate. Record the thickness of the frictionmaterial on service brakes only.

f)- measured friction-material thickness is

less thanmanufacturerspecification or

equivalentindustry standard.If limit isnot available:

- bonded friction-material thickness isless than 1.6 mm

- riveted friction-material thickness is lessthan 3.2 mm without pads removed

- riveted friction-material thickness is lessthan 1.6 mm above the rivet head withpads removed

- difference between inboard andoutboard friction-material thickness is

greater thanOEM standardorindustrystandard.If limit is not available:difference is greater than 3.2 mm

1.6 mm = 2/32 in.

g) clearance between pads and rotor(caliper adjustment)

g)- does not meetmanufacturers

specifications

10. Parking Brake


Note:

Parking brakes that consist of drum-in-rotor type design requires a performancetest. Visual inspection is required, but nodisassembly of the parking-brakecomponents is required.

a) operation

Additional Inspection Procedure(s):- Fully apply the parking brakes and

test according to the transmissiontype.

- Automatic transmission attempt tomove the vehicle in low forward andreverse gear while engine is idling.

- On vehicles with an interlock that

a)- with parking brake fully applied, the

vehicle moves forward or backwardwith little or no resistance




39/96



releases the parking brake uponselecting a forward or reverse gear,the parking brake may be tested by

overriding the interlock (by manuallyengaging the parkingbrake controlwith the transmission in gear).

- Manual transmission with engine atidle, clutch is released until engine islightly loaded in low forward andreverse gear with engine idling.

(i) On vehicles on which the parking brakecannot be tested as noted previously,vehicle must be raised with parkingbrake engaged, transmission not in P

and resistance to rotation checked byhand, for each wheel that is equippedwith a parking brake.

(i) with transmission not in P or manualtransmission not in gear, any wheel witha parking brake can be manually rotated

the parkingbrake does not fullyrelease when the release control isoperated

b) indicator lamp b)- parking-brake indicator lamp does not

activate when control is placed in theapplied position

c) control c)- binds,brokenormissing

- inoperativeor fails to lock

d) cable and/or linkage d)-broken,frayed, improperly secured,

missing,seized or equalizer ismissing

e) adjustment e)- any part of the system is improperly

adjusted

f) friction material f)- friction material must be in place and in

good serviceable condition

g) parking-brake systems with a non-mechanical release system (forexample, spring applied with hydraulic,air or electric release).

g)- the system or any component does not

function as intended




40/96



Note:In addition, the applicable items aboveare to be inspected according to themanufacturers procedure.

11. Anti-Lock Brake System (ABS)


Note:Vehicle with a GVWR of 4,536 kg or lessis not required to have a functioning ABSsystem. An active ABS tell-tale is notcause to fail these vehicles; however,

ABS tell-tale must be recorded oninspection report.

Every motor vehicle manufactured on orafter April 1, 2000, with a GVWR above4,536 kg must be equipped with ABS.

a) ABS fault tell-tale

Additional Inspection Procedure(s):Cycle the ignition off and on whilemonitoring the ABS fault lamp.

Note:Record activetell-tale on inspectionreport

a)- vehicle that requires an ABS system as

per the note:

missingorinoperative(applies only

to those vehicles that requireafunctioning ABS system)

fails to turn on during bulb-checkcycle when ignition is turned on

indicatesthe presence of an activemalfunction by staying on after thebulb-check cycle

any visual evidence that the systemhas beentampered with or defeated

b) electronic control unit (ECU) b)- insecuremounting,missingor

connector corroded

c) wiring

Additional Inspection Procedure(s):Visually inspect accessible portions of the

c)- insecuremounting,missing- conductor is exposed due to damage,




41/96



wiring. Inspect all repairs and damagedareas.

Note:Not required to disconnect.

improper repair or other condition ofwire

- connection or repair does not meet

OEM standard

d) ABS modulating valve d)-missing, insecuremounting to ECU,

level 1 leakor abnormal corrosion

e) wheel speed sensor e)-missing, insecuremounting,

inoperative,connectors corroded

f) ABS system function f)

- there exists evidence that a malfunctionor deficiency in any part of the ABSsystem adversely affects the normaloperation of the service brake systemincluding proportioning of brakingbetween the front and rear axles.

12. Electronic Stability Control System (ESC)


Note:Stability Control Systems are required formotor vehicles manufactured on or afterSeptember 1, 2011, or September 1,2012, for multistage manufacturedvehicles (for example, body mounted oncab and chassis).

If ESC is not required, record activetell-talestatus on inspection report.

a)tell-tale / system status

Additional Inspection Procedure(s):Check for indication of any fault ormalfunction by cycling the ignition off andon while monitoring thetell-tale.

a)

- if ESC is required:

tell-tale fails to illuminate during bulbcheck or tell-tale remains illuminated

fault or malfunction is indicated, or

there exists any visual or otherevidence that the system has been




42/96



tampered with or defeated

- if equipped:

ESC system malfunction adverselyaffects the vehicles brakes orhandling




43/96

Section 4 Steering

Section 4 Steering

1. Steering Control and Linkage


Additional Inspection Procedure(s):Check the steering components listedbelow using tools and methodsaccording tomanufacturerserviceinstructions.

a) steering box or rack-and-pinion unit a)- looseorinsecuremounting; mounting

bolt, bushing or nutmissingorloose- housing cracked,broken,orlevel 2 leak

b) bellow, clamp and boot b)- insecure, missing,split or torn- clampmissing

c) tie rod c)- bent,broken,cracked or welded, or

repaired in a way that does not meetOEM standard

d) adjusting sleeve d)- bent,looseor welded or repaired in a

way that does not meetOEM standard- tightening bolt is in a position that

interferes with normal steering

e) ball-and-socket joints (tie rod, idler arm,drag link, etc.)

e)- bent,insecure, looseor wear exceeds

that specified by theOEMorindustrystandard.

- threads stripped or repaired- damaged, welded or repaired in a waythat does not meetOEM standard

- part is used that does not meetOEMstandard

f) pitman arm f)- bent, damaged,insecureorlooseon




44/96

Section 4 Steering


spline- repaired by welding

g) ball joint in upper or lower control arm g)

- insecure orloosein knuckle or controlarm

- wear exceeds limit shown by wear-indicator,OEM standardlimit orindustrystandardlimit, or is injected with repairmaterial

- Improper,insecureorlooseretainer

h) cotter pin or similar retaining device h)- missing, or deficient part is used that

does not meet OEM standard

i) strut bearing i)- binding or excessive lateral play

j) steering dampener j)- inoperativeormissing- level 2 leak

k) steering column k)- looseorinsecuremounting- mounting fastenermissingorloose

l) telescopic / tilt steering

Additional Inspection Procedure(s):Check the operation of locking device(s).With unit locked, grasp the steeringcolumn and attempt to move ithorizontally and vertically on its mounts.

l)- movement exceedsmanufacturer

specification or, when specification is notavailable, is greater than 6 mm

- column fails to lock into position

m) steering-shaft universal joint and yoke m)- binding,loose,seized, welded or

repaired in a way that does not meetOEM standard

- clamp boltmissingorloose,or splinelooseor stripped

n) steering-shaft slip joint n)- rotational free play between splines

excessive- lateral play excessive




45/96

Section 4 Steering


o) remote (auxiliary) steering control


Operate remote steering from lock tolock to check for proper function.Engine should be running for power-assist steering systems.

o)- steering assembly isinsecureor not

properly mounted

- steering binds- does not operate smoothly or control the

steering throughout the full range oftravel.

- level 2 leakof oil or other operating fluid

p) steering mechanism


Steering mechanism shall be tested forfreedom of movement with the front

wheels on the ground and, where avehicle is equipped with power-boostedsteering, with the engine operating. Turnsteering wheel to full right lock and thenfull left lock.

p)- the front wheels unable to turn from full

right to full left, and back again, withoutinterference or indication of roughness inthe mechanism

2. Power Steering System (Hydraulic / Electric)



Inspect the power steering componentswith the engine stopped. Then, withengine running, turn wheels fully to theleft and right, and check systemoperation.

a) fluid a)- below indicated minimum level or fluid

is contaminated

b) belt

Additional Inspection Procedure(s):Inspect drive belt according to Section 1 Powertrain, Item 9. Engine or AccessoryDrive Belt.

b)

- refer to Section 1 Powertrain, 9.(a),(b),(c) for reject criteria

c) hoses, flexible lines, metal lines andfittings

c)- cracked, worn by or is in contact with




46/96

Section 4 Steering


moving parts- distance to exhaust system component

is less than 25 mm

- level 2 leak

d) pump d)- inoperative, looseorinsecuremounting- level 2 leak

e) cylinder e)- inoperative, looseorinsecuremounting- level 2 leak

f) mounting bracket f)-broken,cracked orloose

- boltmissingorloose

g) assist g)- does notoperate as intended(power

assist provided is noticeably reduced,requiring more than normal steeringeffort to turn the wheels left or right)

3. Steering Operation


Note:Check steering operation after inspectingsteering control and linkage, andchecking power steering as describedabove.

a) steering wheel a)-broken,damaged,looseon spline, or

diameter notOEM standardorequivalent

b) rotation and travel

Additional Inspection Procedure(s):Turn wheels fully to the left and right andcheck system operation.

b)- binds or jams during rotation- number of rotations from centre to full

left does not equal the number ofrotations from centre to full right, +/- turn

- number of rotations from full left to full




47/96

Section 4 Steering


right is less than 2

c) steering lash or free play c)- steering lash or free play exceedsOEM

specifications, or OEMspecification isnot available:

steering free play exceeds the limitsspecified in Table 1, and

for rack and pinion steering systemsthere exists excessive free play inthe steering mechanism

d) tire clearance

Note:Do not reject a vehicle based on evidenceof prior contact between the tire andvehicle parts.

Road test required to verify tire clearanceduring vehicle operation (Section 11).

d)- space between tire and frame, fender or

other vehicle part is less than 25 mm atany point in the turn, while vehicle is atrest

e) steering stop e)- improperly adjusted ormissing

TABLE 1

Steering Wheel Diameter Free Play Shall Not Exceed

Less than 350 millimetres 45 millimetres

350 millimetres and larger, but less than400 millimeters

50 millimetres

400 millimeters and larger, but less than450 millimeters

55 millimeters

450 millimeters and larger, but less than500 millimeters

60 millimeters

500 millimetres and larger 70 millimeters




48/96

Section 4 Steering

4. Kingpin



Raise the axle to unload the kingpin. Turnthe wheels through a full right and leftturn.

a) lateral movement

Additional Inspection Procedure(s):Rock the wheel in and out, by hand orusing a bar, to check for kingpinmovement. Measure lateral movement atthe outer edge of the tire.

Use a dial gauge if necessary.

a)- not withinmanufacturerspecification or

whenmanufacturerspecification is notavailable:

- for wheels under 20 in., lateralmovement is more than 3 mm

- for wheels 20 in. or larger, lateral

movement is more than 5 mm

b) vertical movement

Additional Inspection Procedure(s):Place a bar under the tire and check forvertical movement between spindlesupport and axle.

Use a dial gauge if necessary.

b)- not withinmanufacturerspecification or

whenmanufacturerspecification is notavailable, greater than 2.5 mm

c) condition c)- binding or jamming is detected while

turning wheel




49/96

Section 5 Instruments and Auxil iary Equipment

Section 5 Instruments and Auxiliary Equipment

1. Horn


Additional Inspection Procedure(s):Test horn operation.

Note:Every vehicle must have at least oneoperating horn.

a) operation a)

- inoperative,missingor not clearlyaudible

b) control b)- not identified as Horn, if notOEM- not readily accessible to the driver, if

notOEM