Vehicle structure

Note 1

Front inner guard covers do not need to be completely removed from the vehicle; they can hang from one mounting point provided it is possible to view the structure of the vehicle with the guard cover in that position.

Note 2

Front sub-frame splash guards only need to be loosened so that they can be pulled down and the front underbody structure fully viewed.

Note 3

Pillar trims only need to be completely removed from the mounting surface (they can hang from the seat belt webbing). They do not need to be removed from the vehicle.

Note 4

It is not necessary on all vehicles to remove the ‘A’ pillar trim as part of the structural inspection. The vehicle inspector can ask for the ‘A’ pillar trim to be removed if there is reason to believe that the trim is covering evidence of damage, previous repair or corrosion.

Note 5

Boot sidewall trim only needs to be removed if it is not possible to view the vehicle structure with the trim in place.

Note 6

This is the minimum amount of trim removal necessary to enable a vehicle inspector to identify any damage, deterioration or poor repairs to structural areas of the vehicle. In many instances it will be necessary to remove additional trim (splashguards etc) to enable a vehicle inspector to identify the full extent of the structural damage, deterioration or previous repairs.

2. Before commencing the inspection, the vehicle inspector must check the exterior of the vehicle for any signs of previous crash repairs under appropriate lighting conditions (as specified in section 8(1.3) and (1.6) of the Introduction to this manual). Evidence of previous repairs may be indicated in any of the following ways:

a) mismatch of paint colour or finish

b) uneven ride height

c) wrinkles in side panels, doors and roof

d) misaligned wheels

e) uneven gaps between body panels (fenders, bonnet, doors and boot).

3. The following items must be inspected on each vehicle:

a) Engine compartment

b) Exterior

Note 7

Where a vehicle is fitted with full sill exterior plastic body kits, which completely cover the exterior sill so that it is not possible to remove without damaging beyond repair, the body kit only needs to be removed if the vehicle inspector believes there are underlying problems with the sill.

c) Luggage/cargo compartment

d) Underbody and/or chassis frame

e) Passenger compartment (inside vehicle)

Note 8

The vehicle inspector must fully extend every seatbelt to ensure that the entire length of the seatbelt is inspected.

The underbody inspection must be carried out under specified lighting conditions, using any of the following equipment:

• an inspection pit
• a vehicle hoist
• a ramp of adequate height that allows the inspector to comfortably walk under the vehicle to inspect all crush zones, chassis rails, sills and cross-members.

Note 9

If seatbelt anchorage bolts are removed as part of the structural inspection process they must be reassembled using a calibrated torque wrench.

2 Evidence of inspection

The vehicle inspector must place some form of unique mark to identify the person carrying out the structural inspection (eg inspector initials as identified in the QMS/PRS Staff Record) at each concealed location inspected. This provides evidence of the inspection and a form of quality control.

For all concealed upper and lower outboard seatbelt anchorages, the unique identification marks must be placed within 50mm of these.

3 Reassembly

Where components are removed as part of the inspection process, an IO must have procedures in place to ensure that those components are reassembled correctly.

4 Trim removal exemption

Under some circumstances it is not practicable to remove the trim in a motor vehicle.

Examples of such cases are:

In such instances, IOs may apply to the Transport Agency for an exemption from the requirement to remove the interior trim.

Before Waka Kotahi can process an exemption for a specific vehicle, the IO must structurally inspect the vehicle and complete an application for an exemption from trim removal requirements (see Reference material 18).

Once Waka Kotahi has received the application, a Waka Kotahi Certification Officer or nominated person will contact the entry certifier to arrange a date and time for the vehicle to be inspected.

1. The vehicle should be available on a hoist. The Waka Kotahi staff member or nominated person will advise which items such as door rubbers, inner guards and under body panels need to be removed for the purposes of the inspection.

2. The IO must provide the Certification Officer with a copy of the structural inspection sheet.

3. The Certification Officer will physically inspect the vehicle. Waka Kotahi will consider the following factors when processing an application for exemption from trim removal:

4. If any evidence of structural damage, repairs or corrosion damage is found, the application will be declined.

Note 10

An application may be reconsidered if a specialist repair certifier inspects the vehicle and issues an LT307 certificate (for a light vehicle - see Reference material 79 for a sample certificate) or a statement on letterhead from a heavy vehicle specialist certifier (for heavy vehicles) that confirms there is no damage, repairs or corrosion.

5 The Certification Officer will consider the application and notify the applicant of the outcome.

a) If the Certification Officer considers that stripping the vehicle would not pose difficulties or damage the vehicle, the application for a trim removal exemption will be declined. A letter of notification will be sent to the applicant.

b) If the Certification Officer believes there is sufficient reason to grant an exemption from trim removal requirements, the Certification Officer will approve a full or partial trim removal exemption. An ‘exemption to remove trim on an imported used vehicle’ letter describing any special conditions will be sent to the entry certifier, and a copy will be sent to the applicant.

IMPORTANT: Technical bulletin 11 describes the requirements for carrying out the inspection of motorhomes.

Note 11

Specialist repair certifier in this case means a light vehicle repair certifier or heavy vehicle specialist certifier as applicable to the vehicle class.