Looking to become your modified auto engineering certified and route legal? You're in the right place. In this article I'll do my best to explain the whole process from starting time to stop, the steps involved and what to expect. This article is written specifically for the state of New South Wales, Australia, but the process is likely similar in virtually places around the world. If y'all're not in NSW, make sure you lot check with your local regime or engineer and they will exist able to explain the relevant process and any variations.

This commodity is written based on my own personal experience having recently gone through the process. Your journeying may exist different, then please take this as a guide and not pure gospel.

Firstly here'due south an overview in video form….


Why get your car engineer certified?

A defect find may exist the least of your worries.

There are many reasons to get your modified auto engineer certified. The nigh obvious reason is to avert heavy defect fines or possible de-registration (ruddy sticker) of your vehicle due to it beingness deemed un-roadworthy past the Police. In NSW, police force are ever more frequently setting up complex defect stations, where qualified inspectors check over the details of your car. These checks ofttimes involve tests for noise, also every bit other obvious things similar running atmospherically venting blow-off valves, or exhaust systems without emissions control equipment (catalytic converters). However an frequently overlooked attribute is the implications on insurance. When it comes to modifying cars, yous're basically guilty until proven innocent. A car with certain modifications that hasn't been certified is technically un-roadworthy, and you lot can cease upwards finding yourself in a state of affairs where your insurance policy is void even though it "covers all legal modifications". This can too impact your 3rd party insurance. For example, if your automobile has modified brakes or suspension which take not been certified, and these are determined to be a contributing cistron to an accident, you could detect yourself having to pay for 3rd party damages, medical bills, etc. So as y'all can see, this is serious business and not a risk to be taken lightly.

What modifications need to be engineer certified?

This is a relatively complex question, and the regulations change somewhat oft, then if y'all are unsure whether or not your mods demand to exist certified it's e'er all-time to telephone call an engineer and ask them. However as a basic rule, and modification which could be considered relevant to safety, and hasn't gained Australian Design Rules (ADR) certification for the machine you're fitting it on volition demand to be certified. For example, if you install a gear up of tail lights that are marked as certified to the relevant standards, you will non need an applied science certificate. But if you buy tail lights which practise not already carry the relevant standard certification from manufactory, and so technically these would demand to be certified. Y'all may be thinking "why would I bother paying to have an engineer certify a modern a simple as tail lights? Well as we touched on earlier, if you were in a rear end accident and the police and/or your insurance company determined the tail lights to be a gene due to not being certified to Australian standards, you lot could be found at fault, and your insurance could exist invalidated. Other modifications which require certification if not already carrying the relevant approving include but are non limited to:

  • Modifications to brakes. Not pads and rotors that run across OEM specification or greater, but restriction lines and calipers, master cylinders and ABS modules, difficult lines, etc.
  • Modifications to pause such as replacement shocks, air bags, etc. Springs are typically OK unless they lower the car to 100mm ground clearance or less, or accept been chopped or clamped).
  • Power increasing modifications such as forced consecration kits.
  • Whatsoever exhaust modification which removes emissions equipment (if you lot remove emissions equipment, chances are you won't be able to pass emissions testing. More on this afterward).
  • Any increase in wheel/tyre bore/width beyond the largest size that'southward offered on your car as a factory option. (This rule seems to alter all the time, check with your engineer).
  • Any modification which alters the car's crash dynamics, such as modification or aftermarket replacement to the crash bar to fit an intercooler, replacement fiberglass or carbon fiber body panels, door hinges.
  • Whatever modification which may interfere with the supplemental restraint arrangement (air-bags). This includes annihilation which may interfere the the air-bags themselves, such as aftermarket steering wheels or gauge pods, but as well anything that may interfere with the air handbag sensors, such as plumbing fixtures a front mounted intercooler or oil cooler.
  • Retrofitted engines, gearboxes, differentials, etc. (As a basic rule, the engine your swapping in can't be older than the engine that's being removed, just check this with an engineer before you lot brainstorm your project).
  • Whatever modification which alters occupant entry/exit, or locking of the vehicle, such as shaved door handles, Lamborghini manner doors, etc.

What are the steps involved?

The engineering procedure itself consists of the post-obit stages:

  • Emissions test (IM240)
  • Brake Test (if modified)
  • Engineer inspection and Test Drive

If the car has already been de-registered due to an outstanding defect find, you volition also need to get a bluish slip inspection.

Each step in the procedure can quite circuitous, and then allow's take a expect at each in more detail. As each step in the process may fail, information technology's a expert idea to have a back upwardly plan (mechanic/tuner on call, etc), particularly if your car already has already been de-registered and you're planning on towing it to emissions testing or the engineer. In many cases information technology's more than cost effective to simply enquire your tuner or mechanic to handle the whole process on your behalf, rather than fork out the cost of towing and taking time off work to handle everything yourself. Something to continue in mind anyway. Let's get started.

Emissions test (IM240)

Passing emissions is typically the almost difficult office of the engineering procedure, particularly if you ain a newer model car. Australian standards stipulate the acceptable emissions for vehicle's manufactured within sure engagement ranges. The newer the machine, the stricter the standards.

You can download a copy of the current NSW standards here.

The IM240 emissions test is a 240 second simulation examination that runs the motorcar through a range of engine load scenarios on a dynamometer. A gas analyser is inserted in to the exhaust, and noxious gasses are tracked in grams per km.

The gasses tracked are HC, CO, NOx and PM (depending on the age of your automobile, refer to the standards above). If any of these gasses exceed the full output limits in grams per km equally stipulated past the standard relevant to your car at the completion of the test, the result is a fail.

The emissions testing facility at Botany.

A lot of tuners are not familiar with the details of the test process, and therefore aren't clear on exactly what'due south required in order to laissez passer the exam. This oftentimes results in a lot of trial and error. It's not uncommon for cars to fail the exam a number of times while the tuner figures things out. At a basic level, it ultimately comes down to a balance between running rich enough to go along the engine safe, and lean enough to pass the test. Every bit the IM240 exam runs through a variety of load and RPM scenarios in different gears, information technology'due south of import that the tune be emissions friendly beyond the unabridged scope, not just a ability run. Opposite to popular belief, stable air/fuel ratios in the vicinity of 14.vii practice not guarantee a laissez passer by any ways. Choose your tuner wisely.

The full IM240 test procedure is explained in this certificate published by the EPA (starting on page 12). I highly suggest you print this out and requite it to your tuner and so they take a guide to work from. This will greatly increment your chances of passing first go.

Your car will besides need at least one catalytic converter installed to have any chance at passing the test, so don't bother showing up with a straight through track pipe! Likewise, a visual inspection may be done, and so if you accept an atmospherically venting blow off valve, or oil vapour catch cans, cheque with your engineer to run across what's required to make them legal before taking the automobile for an emissions test. As well, whatever frazzle or vacuum/heave leaks volition result in a fail.

Note that dissonance levels are not factored in to this test, however they will be factored in by your engineer during their inspection, so you lot're unlikely to get through with a cannon installed.

How practice I go my car tested?

In NSW, at that place are ii authorised emissions testing facilities. One in Botany, and one in Penrith. These are run by Roads and Maritime Services and are a free service offered by the NSW authorities in order to encourage people to keep their cars roadworthy. Squeamish!

You'll demand to call upward Service NSW on 13 77 88 and make a booking. At the fourth dimension of writing, the Botany center is open up every Wed, and the Penrith center opens whenever the demand is high enough. When they answer the phone, only tell them you demand to volume a light vehicle emissions test. They'll put you through to the relevant department. Look to be on concord for 15-thirty minutes at this phase.

They will ask you for your licence number and the vehicle'southward registration, and ask you to be there 15 minutes prior to your booking. Y'all're typically able to get a booking about a calendar week in advance. Y'all tin also make multiple bookings if you wish to do then. Information technology'due south a slap-up idea to book one test in the early morn, and another in the afternoon. This gives yous time to re-tune, or make any necessary frazzle system changes without having to await a whole week to try again.

On the solar day of your booking:

Go to the function and permit them know you've arrived. Although non 100% necessary, it's a good idea to leave your car running if possible. This means the catalytic converters will stay hot, which could be the difference between a pass and fail result. Catalytic converters retain a lot of heat for a long time, and so driving the motorcar hard on your way to the test is a good thought to brand certain in that location's as much heat in them as possible, and therefore run equally efficiently as possible.

One time you're called, your car volition be taken in to a sealed testing room with a dynamometer. You volition not be immune inside, nevertheless at the Penrith facility, there is a viewing window and so you lot can encounter what'southward going on. The testing officer has a display in front end of them which prompts them to accelerate, shift gears, etc, in order to follow the simulation. A gas analyser is inserted in to the exhaust to measure the emissions. They don't make any physical changes to the machine or "install" anything. The only thing they volition practice is plow of traction control (required past the test procedure).

Inside the testing facility at Botany.

The car will be run through the exam sequence in one case to warm up the engine and catalytic converters. Then the test will begin. If the motorcar fails, the testing officer will give you a printed report showing the areas during the test where output where emissions were likewise high, and run yous through the results (they're actually friendly guys). Unfortunately, the graphs they supply only evidence gas levels over time, so you'll demand to refer back to the test procedure to quantify the data and see what needs to be altered in society to pass side by side fourth dimension. Look at the time on your graph, and see what speed/gear it relates to on the chart. This will permit you to effigy out the RPM at the bespeak that the car failed, which volition help to tune out the issue.

If the auto passes, they volition run through the test over again to verify the result, and requite yous a impress out of the report to give to your engineer.

Don't worry if you fail. They won't ruby sticker y'all or issue a fine, so you can still bulldoze the auto. Still they volition keep a record of the result, along with your registration, engine number and VIN. So information technology'southward in your best interests to go the car retuned and tested over again ASAP.

As of now (May – 2015), the RMS do non keep a record of the modifications done to the car when doing emissions testing, this makes it tempting to return the car to stock exhaust, etc, and run a different engine map in order to pass emissions. Then change back to the previous setup once the car has passed. You exercise this at your ain risk. Just because your car has passed emissions and has applied science certification DOES NOT mean you have amnesty from the police. Should you exist pulled over, the constabulary tin still issue you with a defect notice or red sticker if they believe you have changed something, and send you off to the EPA for another examination to verify the auto is however roadworthy. Your engineering certificate is as well useless if you lot change listed equipment after information technology's been issued, so if you're going to go through the procedure, it's far meliorate to do it properly. Remember, "Guilty until proven innocent". The same insurance implications also use here, and then it'southward very much in your best interest to non endeavor and take reward of the organisation and do things by the volume.

Brake Exam:

This is the easiest part of the process, as not many of u.s. would be driving a machine with dodgy brakes ( I hope). Merely take your car to an MTA approved mechanic and ask them to practice a "Brake-Testa" brake test. This is exactly the same test they practice when getting your pink slip rego inspection in an older car. The testing officer will requite you lot a pocket-size slip of paper with the result, give this to your engineer.

Obviously if for some reason the car fails, rectify whatsoever issues are causing the failure and endeavour again.

Engineer inspection and Test Drive:

If you lot've been sensible with your modifications and done your research, this part of the process should exist pretty straight forward. Your engineer volition probable ask you lot to supply a listing of all the modifications done to the vehicle as a starting indicate before they do their inspection (so have your build log ready). This enables them to allow y'all know if they spot any obvious problems that volition prevent certification, and what you lot demand to practise to gear up them before wasting time doing their inspection and test drive. Cost will also depend on the level of modification to your vehicle. My auto was $900AUD with brakes, break, exhaust and aftermarket supercharger kit, but no modifications to the fuel system or frame/chassis.

Provided there are no obvious problems from your list of mods, you'll and so adapt a time for them to do their visual inspection and examination drive. The time information technology will accept depends on the extent of the modifications, so speak to your engineer to run into how long they will need your car for.

If in that location are whatever problems that need to be rectified before the car can be certified, your engineer will let you know, and y'all can arrange to accept them fixed.

In one case everything is sorted out, the engineer will produce a written report for you lot, listing the mods that need to be certified. This report is also lodged with the RMS and so that they accept a record. Until this has been done, the vehicle is still technically un-roadworthy.

In NSW, it's not necessary to have a physical modification plate affixed to light vehicles, however it is a requirement in QLD (I'm not sure about other states). Then your engineer may likewise practice this.

Anything Else?

If your car has no outstanding defect notices, you lot're now good to become, provided the RMS accept received the paperwork from your engineer. Nonetheless if the machine has been de-registered, or has an outstanding defect notice, now is the time to take it to an RTA inspection middle and have a bluish skid inspection done to clear the defects.

That'south information technology! I hope this article has helped you to better empathise the procedure of getting your car modified car road legal. The risk of getting caught may be small, but the potential implications are huge, with non simply massive fines for removal of emissions equipment, but potential for void insurance including threerd party insurance.

The NSW Government are actually clamping down on illegally modified cars lately, particularly with the recent media attending related to "hooning". Past doing the right matter, not only do we non accept to worry about getting disrepair, just we also improve the modified motorcar scene and remove a lot of the negative stigma attached. Win/Win!

I hope you've institute this article helpful and all-time of luck with your project!

Whatsoever questions or comments? Or seen something you don't remember is quite authentic? Hit upwards the comments below…… As I said at the starting time. This article is based on my own journeying, so if you accept anything to add based on your experience, please practise contact me!