Cars

Vehicle standards and specifications for cars including brakes, engine and exhaust modifications, fuel systems, and wheels and tyres.

Fitting an aftermarket blow off valve can affect the vehicle's compliance with the exhaust emission requirements specified in the Australian Design Rules, and is therefore not acceptable.

External wastegates on turbocharged engines are not permitted.

The use of bonnet pins that protrude through the bonnet is not acceptable.

Bonnet pins that were original equipment from the manufacturer may be acceptable. Bonnet securing devices that are flush with the contours of the bonnet may be used.

Mascots are acceptable if they were provided as original equipment by the manufacturer for a particular make and model of vehicle.

For more information read MR1457 (685.6 KB PDF)

Fitting a bonnet scoop (forward or rearward facing) to a motor vehicle is only acceptable provided that it is designed, built and fitted in a way that minimises the likelihood of injury to a person accidentally making contact with the vehicle.

For more information refer to Bonnet scoops.

It is recommended that braking modifications are carried out using production components that themselves do not require modification.

Requirements for upgrading brakes

When brakes are upgraded using components or systems which were not standard options for the vehicle, a Statement of Requirements or a report from a light vehicle engineering signatory may be necessary.

When the brake system of an early model vehicle is modified, it is recommended that a dual or split circuit brake system be fitted.

If brakes are upgraded - eg front brakes changed from drum to disc, it is essential that:

• the correct master cylinder is fitted
• the brake master cylinder has adequate brake fluid in the reservoir (disc brake systems usually require a larger reservoir)
• front to rear brake balance is compatible and does not result in excessive wheel lockup of one axle during braking
• all components of the braking system are compatible and are unmodified
• the installation is in accordance with the manufacturer's specifications
• all brake tubing and flexible brake hoses must conform to Australian Design Rules.

Alterations to brakes

Brakes must not be altered in any way that would reduce braking efficiency. This includes fitting smaller drums or discs and machining drums or discs beyond the limits set by the component manufacturer.

All brake components shall clear other vehicle components such as wheels, suspension and steering components.

Brake components and brake lines must be mounted in areas where they are not likely to be struck by objects thrown up from the road. They also must be protected from excessive heat and abrasion. The use of copper tubing for hydraulic brake pipes is not allowed. Joining hydraulic brake pipes by brazing, silver soldering, etc is not allowed.

Brakes on light trailers

For information on the requirements for brakes on light trailers see Light vehicle towing and trailer regulations .

On vehicles manufactured on or after 1 July 2013 with a gross vehicle mass (GVM) less than 3.5 tonnes bull bars must conform to the shape of the vehicle.

Over time, this will eliminate aggressive upright or forward-facing bull bars being fitted in South Australia.

Bull bars must be designed and fitted so that the safety of the vehicle is not affected and not be of danger to other road users including pedestrians.

Bull bars must be fitted correctly and be free of sharp protrusions. They must not obscure the driver's view or any vehicle lights including indicators.

Fitting fishing rod holders to the front of a bull bar is not acceptable.

Requirements

All bull bars fitted to vehicles manufactured on or after 1 July 2013 with a GVM of not more than 3.5 tonnes, must comply with the design and installation requirements of Australian Standard AS4876.1-2002 'Motor Vehicle Frontal Protection Systems Part 1- Road User Protection' (except clause 3.2).

This is consistent with the Road Traffic (Light Vehicle Standards) Rules 2018 made under the Road Traffic Act 1961.

In summary

• The profile of the bull bar should follow that of the vehicle in plan, side and front view, and not extend excessively beyond the side profile of the vehicle.
• The bull bar must be designed and fitted so that the safety of the vehicle is not adversely affected.
• It must be firmly and securely mounted and supported, and must not constitute a danger to other road users.
• The bull bar and any fittings, hooks or attachments must not have any sharp edges, corners or protrusions. All exposed sections of the bull bar and fittings must be radiused and deburred.
• The bull bar, together with its mountings and any winch or other equipment and fittings, must be taken into account for vehicle dimensions and shall not increase the overall width of the vehicle.

Airbag and additional fittings requirements

Vehicles fitted with an airbag or manufactured to comply with Australian Design Rules (ADR) 69 or ADR 73 on Occupant Protection, can only be fitted with a bull bar that has been certified by the vehicle manufacturer as suitable for that vehicle, or has been demonstrated by the bull bar manufacturer to not adversely affect the vehicle's compliance with ADR 69 or ADR 73 or interfere with any critical airbag timing mechanism.

Additional fittings such as driving lamp brackets, fishing rod holders or aerial mounting brackets must not protrude above the top or forward of the bull bar.

• Australian Design Rule (ADR) 69 - Full Frontal Impact Occupant Protection 2006
• Australian Design Rule (ADR) 73 - Offset Frontal Impact Occupant Protection 2005

Failure to comply

Bull bars that do not meet Australian Standard AS 4876.1 - 2002 (clauses 1, 2, 3.1 excluding clause 3.2) that are fitted to vehicles manufactured on or after 1 July 2013 with a GVM of not more than 3.5 tonnes may breach a vehicle standards requirement and contravene sections 117 and 118 of the Road Traffic Act 1961.

The vehicle's driver or operator may be summonsed to Court and face penalties or be issued with an expiation fee.

Defect notices for deficiencies caused by a breach of a vehicle standards requirement may be issued for such vehicles under section 145 of the Road Traffic Act 1961.

Design and construction

Light vehicle front protection systems - safety considerations

Approval is not required to change the colour of the vehicle.

To notify of a colour change, complete an MR7 Application to alter vehicle or trailer detail (185.6 KB PDF) and submit it to any Service SA centre.

Lengthening or shortening a vehicle body is acceptable provided an engineer's report prepared by a light vehicle engineering signatory is presented, certifying that the modified vehicle:

• continues to comply with all applicable Australian Design Rules
• meets the requirements of Brake system test procedure
• meets the requirements of Lane change manoeuvre test procedures
• meets the requirements of Torsional rigidity and beaming stiffness test procedures.

You will need to submit an  Application to modify a light motor vehicle for any chassis modification and a statement of requirements will be issued prior to the roadworthy inspection.

Application to modify a light motor vehicle

An alternative engine may be fitted to replace one that is no longer serviceable or to achieve an increase in capacity, power and torque.

If the engine in your vehicle has been changed with no modification and is an available option or standard specification for your vehicle make, model and year, complete MR7 Application to Alter vehicle or trailer details (185.6 KB PDF) form and submit it to Service SA for approval.

If approved, you will be notified of the change.

Engine changes, statement of requirements

Certificate of exemption

Emission requirements for passenger vehicles operating on petrol

Exhaust systems and noise

In modern vehicles, the engine management system (computer) is an integral part of the emission control system.

Re-calibrating the engine management system either by changing the chip, re-programming, or replacing the unit with an aftermarket computer may result in non-compliance with the emission control Australian Design Rules (ADRs) applicable to the vehicle.

Testing a production vehicle for compliance with ADR emission control standards is a lengthy and expensive process and can only be undertaken with testing equipment acceptable to the Department for Infrastructure and Transport (DIT).

DIT may consider the fitting of an aftermarket engine management system where an engine upgrade takes place, however, this will be on the condition that an IM240 emission test is performed.

An Application to modify a light motor vehicle form must be submitted to Vehicle Standards.

Application to modify a light motor vehicle

The use of custom made fibreglass or carbon fibre body panels is acceptable provided that the structural integrity of the body is not adversely affected and the vehicle continues to comply with all relevant Australian Design Rules.

When fitting a carbon fibre bonnet, it must be manufactured in a way that it:

• is of equal strength to the original
• retains the under-bonnet ribbing/structure
• is mounted using the original bonnet catch and hinges.

Fuel lines

Fuel lines must meet the following requirements:

• The material used for fuel lines must be a suitable grade for use with automotive fuels.
• Fuel lines must be securely fastened and must not leak.
• Push-on-type hose connections must be fitted with hose clamps or clips.
• Fuel lines must be clear of the exhaust system and any turbocharger.
• Where fuel lines pass through panels, bulkheads or the chassis they must be adequately supported and protected from chafing or damage.
• When fitted under a vehicle, fuel lines must be protected from road debris and damage either by chassis or body components by shielding.

Fuel filters and pumps

Additional fuel filters and alternative or replacement fuel pumps may be fitted provided that:

• the installation is in accordance with good engineering practice
• no pump, fuel line or filter is located within the occupant compartment or boot
• all components are unmodified
• the fuel pump stops when the ignition is in the off position
• the alternative/replacement fuel filter or the fuel pump is secured and shielded against heat and damage
• and that there are no leaks.

LP gas or petrol and LP gas

Vehicles that are equipped to operate on dual fuel - eg the vehicle can operate on either petrol or liquefied petroleum gas (LPG) - must retain all original emission control equipment, except for the air cleaner, carburettor, heated inlet air, and associated equipment. These may require modifications to facilitate the installation of the LPG intake system.

The vehicle must also comply with petrol-related regulations. Any emission control systems that were fitted eg catalytic converters and oxygen sensors - must remain operational.

Conversion of a vehicle to operate on LPG must be performed to AS/NZS 1425 - LP Gas Fuel Systems for Vehicle Engines.

Only a licensed person is allowed to install or repair LPG equipment. A current identification plate must be fitted to certify that the LPG system meets the requirements of AS/NZS 1425.

Dedicated (single) fuel

Vehicles that are not required to comply with Australian Design Rule (ADR) 37 (pre 1 February 1986), and which are running solely on LPG, need not be fitted with emission control equipment, provided that the following requirements are met:

• The vehicle exhaust emits less than 4.5% carbon monoxide at recommended engine idle speed.
• The petrol pump, fuel tank, carburettor, fuel supply lines, and any other associated equipment related to the petrol fuel system are removed from the vehicle.
• Vehicles built to comply with ADR 37 and later, must retain all emission control equipment including the catalytic converter.
• From 13 December 1993, vehicles originally designed to operate with a closed-loop engine management system must have an LPG closed-loop management system installed which results in exhaust emission levels for LPG operation that are not inferior to the levels produced by the original vehicle prior to LP gas fitting.

Replacement fuel tanks

Fitting replacement or additional fuel (petrol) tanks to vehicles manufactured prior July 1976 does not contravene the requirements of Road Traffic Act and Regulations, provided that sufficient ground clearance is retained and they are fitted outside the passenger compartment.

For vehicles manufactured on or after 1st July 1976 the ADR requirements for evaporative emission controls must be met, including:

• All fittings and devices fitted to the fuel tank by the vehicle manufacturer must be retained or duplicated and operate correctly.
• The fuel tank and filler shall be arranged so that any overflow or leakage of fuel cannot accumulate or contact the exhaust or electrical systems.
• Fuel tanks fitted to the vehicle are normally required to be filled and vented externally.
• If a filler inlet is located inside a vehicle, it must not be inside the passenger compartment and the inlet must be separately sealed from the rest of the vehicle to ensure fumes or spilled fuel cannot enter the passenger cabin.
• There must be no lights or electrical wiring in the area where the fuel filler is located.
• The minimum ground clearance of 100mm must be retained.

An object fitted to a vehicle must be designed, built and fitted to the vehicle in a way that minimises the likelihood of injury to a person making contact with the vehicle.

However, if the vehicle was designed before 1965 and such object was part of the design of the vehicle this may be permissible.

All equipment inside the vehicle such as fire extinguishers, GPS navigation or additional gauges should be securely fastened.

It is recommended that cargo anchorage systems should be capable of withstanding a force equal to twenty times the mass of the equipment.

Cargo barrier protection screens are available for many station wagon and light commercial vehicles and are highly recommended.

No vehicle may be equipped with:

• any object or fitting not technically essential to the vehicle eg fishing rod holders.
• any object or fitting technically essential to such vehicle unless its design, construction and conditions and the manner in which it is affixed to the vehicle reduces to a minimum the risk of bodily injury to any person
• any object or fitting which, because it is pointed or has a sharp edge, is likely to increase the risk of bodily injury to any person
• any bumper bar, the end of which is not turned towards the body of the vehicle to a sufficient extent to avoid any risk of hooking or grazing.

For more information read Hazardous projections.

Intercoolers can be fitted to vehicles providing:

• there are no sharp projections ahead of the front bumper that may increase the risk of injury to other road users, including pedestrians
• the intercooler is fitted and secured in a manner in accordance with normal automotive engineering practices, and the structural integrity of the vehicle has not been affected
• adequate provision is made for a complying number plate to be fitted in an approved position.

Lighting

Front fog lights

Coloured lights

Daytime running lamps

LED Light Bars and additional driving lights

HID (high-intensity discharge) headlamps

Instrument panels

Visual display screens

Mudguards must be fitted to all road wheels and must cover the full width of the tyre when viewed from directly above.

They must prevent direct contact with the upper half of the wheel in forward collisions and be designed to reduce the dangers to road users from contact with moving wheels.

They must deflect downwards any stones, mud, water or other material thrown upwards by the rotation of the wheels.

For vehicles manufactured on or after 1 July 1988, specific requirements relating to the design and construction are contained in Australian Design Rule 42.

The wheel guard including the mudflap (if fitted) must be no higher than 230 mm from the ground and for off-road vehicles no higher than 300 mm from the ground. For more information on this requirement see the Road Traffic (Light Vehicle Standards) Rules 2018.

An oil catch may be fitted provided it is vented back into the vehicle's crankcase so that oil or fumes do not escape to the atmosphere.

Venting any engine emissions to the atmosphere is not permitted.

Seats

Additional or replacement seats must be installed in accordance with the current issue of Vehicle Standards Bulletin 5 - Manufacture and installation of additional seats.

The addition or removal of seats requires a seating inspection by the Department for Infrastructure and Transport (DIT).

The vehicle will then be fitted with a seating label to reflect the new seating arrangement.

The removal of seats or seatbelts to achieve a reduction in seating capacity must not interfere with the vehicle's supplementary restraint system (SRS) - eg removing a front seat and seatbelt with pre-tensioners may disarm the entire vehicle's SRS and therefore would not be approved.

Temporary removal of seats

Many 4WD owners who use their vehicles for holidays and camping sometimes would like to use the rear space of their 4WDs for camping equipment or for extra luggage room. Therefore it would be useful to temporarily remove the rear most seats in the vehicle.

If the removal of seats is temporary DIT does not need to be advised, and no seating inspection is required.

If the seat cannot be returned to its original position because of the permanent removal of an anchorage point, then a seating inspection is required and Service SA will need to be notified of the change.

The temporary removal of seats in vehicles in particular to 4WD's with rear seats for seven or eight passengers, is permissible providing that:

• when removing rear seats that no tools or only simple tools are required
• no seat, seat belt or child restraint anchorages are removed or modified and no modification has been made to the seating capacity
• there are no structural modifications involved and there is no change in the vehicle's registration category.

Seat belts

Under the Road Traffic Act and Regulations seat belts are required in the driver's and front outboard seating positions from 1 July 1967.

Seat belts for all front seating positions became mandatory from 1 January 1969 and for all seating positions from 1 January 1971.

The level of safety provided by seat belts must not be reduced. Seat belts must not be replaced by belts of a lesser design rule standard.

A person must not sell a seatbelt or part of a seatbelt for use in a motor vehicle that has previously been installed in another vehicle.

There is no objection to seat belts of a higher standard being fitted, however it is recommended you contact DIT for advice to ensure that the belts are of the correct type and can be correctly fitted.

Seat belt anchor points are carefully chosen and tested by the vehicle manufacturer. Therefore it is not permitted to alter the location or the strength of the seat belt anchorage points without advice from a Chartered Professional Engineer.

Fitting harness belts to passenger vehicles manufactured on or after 1 January 1969, but prior to 1 January 1975, will only be considered on presentation of an engineering report prepared by a Chartered Professional Engineer that demonstrates continued compliance with Australian Design Rule 5A and that there is no rear seating position.

Australian Design Rule 5A - Seat Belt Anchorages

Fitting harness seat belts to passenger vehicles manufactured to comply with Australian Design Rule 4B manufactured on or after 1 January 1975, is not permitted as the Australian Design Rule requires the inclusion of a dual locking retractor system.

Australian Design Rule 4B - Seat Belts
Light vehicle engineering signatory

Cosmetic body modifications such as wheel guards, side skirts and front or rear spoilers are permitted without approval provided that they are fitted with regard to the safety of other road users.

Front spoilers must meet ground clearance requirements of 100 mm. It is recommended that the airflow for the brake cooling is not adversely affected.

Rear spoilers must be within the original body profile of the vehicle.

There must not be any sharp edges that could increase the severity of injuries to pedestrians and other road users. See also  Hazardous projections.

The fitting of a rear spoiler that incorporates a brake light requires any originally fitted equipment eye-level brake light to be disconnected.

Steering conversions

All vehicles converted from left-hand drive to right-hand drive must be converted in accordance with the Code of Practice for Steering Conversions for Left Hand Drives.

Vehicle Standards Bulletin (VSB) Number 4 National Code of Practice - Steering Conversions for Left Hand Drives Vehicles.

An engineering report prepared by a light vehicle engineering signatory must be submitted specifying that the requirements of VSB Number 4 have been met.

For all steering conversions, an application to modify should be sent to Vehicle Standards. You will be sent a Statement of Requirements to complete.

Application to modify a light motor vehicle

The statement of requirements is required by Department for Infrastructure and Transport before a vehicle can be booked for inspection.

Vehicles fitted with welded steering components must comply with the requirements set out in VSB Number 4. Welded steering components are not acceptable unless certified by a chartered professional engineer.

Modified steering components

Welding, heating or chroming axles, stub axles, steering arms and steering knuckle supports are not acceptable unless an engineering report prepared by a Chartered Professional Engineer, is presented, which demonstrates that the modifications are at least as strong as the original and contain no latent defects.

Light vehicle engineering signatory

Steering wheels

Steering wheels are designed to minimise injury to the driver during a vehicle accident.

When replacing a steering wheel make sure that the new steering wheel complies with Australian Design Rule (ADR) requirements.

Replacement steering wheels must not be less than 330 mm in diameter. If the original steering wheel was designed with a recessed or padded hub, the replacement wheel must be of a similar design.

A non-standard aftermarket steering wheel may be fitted to passenger cars and derivatives manufactured prior to 1971. When selecting a replacement steering wheel ensure that it is firmly padded and is constructed so that it will bend on impact without splintering or cracking, and that no parts of the wheel are loose or cracked.

Passenger vehicles built after 1970 are required to comply with ADR 10. The replacement steering wheel must have the appropriate markings indicating that it complies with ADR 10. There are a number of steering wheels certified to ADR 10, so before purchasing an aftermarket steering wheel contact Vehicle Standards to ensure that it is acceptable.

Passenger vehicles manufactured after June 1995, which are required to comply with ADR 69 (full frontal impact occupant protection), may only be fitted with steering wheels certified by the vehicle manufacturer as suitable for that vehicle.

For example, if your vehicle has an airbag steering wheel as standard, the replacement must be the same. Fitting an aftermarket steering wheel to a vehicle that has an airbag in the original steering wheel is not acceptable.

Suspension modifications

'Tilt front' is a term used to describe a type of forward pivoting integral engine bonnet, grille and front mudguard assembly for front engine vehicles.

Examples of production vehicles fitted with this type of engine access are the Jaguar 'E' type and the Chevrolet Corvette.

The fitting of a tilt front is only acceptable if:

• The new body sections are designed and constructed with no dangerous or sharp projections so that in the event of an accident the risk of injury to pedestrians and cyclists is minimised.
• The new body sections do not obstruct the visibility of lamps fitted to the front of the vehicle, particularly the direction turn signal lamps (indicators) or headlamps.
• The new body sections do not obstruct the field of view of the driver.
• The field of view requirements are determined as follows:
  • with the driver's seat in the rearmost position, it is possible to see, unobstructed for the full width of the vehicle, a line drawn on the roadway 11 metres ahead of the driver's eye position when looking over the bonnet
  • for the purpose of this requirement the driver's eye position shall lie at the bottom of the 95th percentile eye ellipse (reference Australian Design Rule (ADR) 15/01 clause 15.1.5.1)
  • alternatively, the driver's eye position can be taken as a point 750 millimetres above and 270 millimetres forward of the junction of the seat cushion and seat squab with the seat in the lowest and rearmost position
  • all lights fitted to meet the requirements of Road Traffic (Light Vehicle Standards) Rules 2018 and where applicable Australian Design Rule 6/00 the anchoring, hinge and latching mechanisms are durable and have sufficient strength to secure the hinged section.

The Department for Infrastructure and Transport may request a submission from a Chartered Professional Engineer if doubt exists concerning the strength of components.

In the case of passenger cars and derivatives manufactured on or after 1 January 1969, in addition to the above, an engineering report presented by a Chartered Professional Engineer demonstrating that the vehicle continues to comply with Australian Design Rule requirements, may be required.

Alteration to an engine's turbo boost pressure is not acceptable. This is specified and set by the vehicle manufacturer to ensure compliance with the Australian Design Rules.

Turbo-charging or supercharging an engine increases the power of the engine and may increase the exhaust emissions, fuel consumption and reduce the service life of the engine.

Passenger cars and passenger car derivatives (car type utilities and panel vans) manufactured prior to 1 July 1976 and fitted with petrol engines can be fitted with a turbocharger or supercharger to the original manufacturer's engine without DIT approval.

For cars manufactured on or after 1 July 1976 the fitting of a turbocharger or supercharger requires one of the following:

• the vehicle is fitted with a Second Manufacturer's plate to demonstrate compliance with all Australian Design Rules
• the vehicle to pass an IM240 emissions test
• the converted vehicle is identical to the production turbo/supercharged vehicle.

In all cases a statement of requirements is required and the vehicle must pass a roadworthiness inspection.

Certification from a professional engineer may also be required. See the list of qualified engineers recognised by DIT -  light vehicle engineering signatory

Turbo timers are not to be fitted to vehicles manufactured on or after 1 January 1972.

Australian Design Rule 25 (Anti-Theft Lock) requires that the normal function of the engine only occurs when the ignition lock is in the engine 'on' position.

Fitting wheel tubs ie alterations to the inboard structure of the rear wheel housing, is acceptable provided that:

• the modification does not weaken the vehicle's structure
• there are no modifications to body structural members, chassis members or suspension mounting points and that there are no body modifications undertaken within 200 mm of any seat anchorage or seat belt anchorage.
  Alterations may be permitted provided that an engineering report prepared by a Chartered Professional Engineer is submitted demonstrating that the original strength has not been decreased.
• wheels or tyres do not foul any part of the vehicle's suspension, brake lines or bodywork for the full range of suspension movement.

Since 1973 all cars are fitted with a tyre placard (usually fitted in the glove box, the engine bay, or on a door pillar). This specifies the wheel and tyre combinations recommended by the vehicle manufacturer. It also specifies load capacity, speed rating and the recommended tyre air pressure.

Replacement wheels

Wheel track

Tyres

Surface films reduce light transmission through windscreens and windows. This can significantly reduce a driver's vision, particularly at night and during periods of low visibility.

The windscreen of a motor vehicle must have a luminous transmittance of at least:

• 75% for a motor vehicle built after 1971
• 70% for any other motor vehicle.

The windscreen of a vehicle cannot be fitted with a film that reduces visible light transmittance except for the area above the highest point swept by the windscreen wipers or the upper 10% of the windscreen.

If the windows of a motor vehicle are coated to reduce light transmittance, the following requirements apply:

• visible light transmittance must not be less than 35% when measured through glass and the film together
• reflectance in the visible light range must not exceed 10%.

For more information read Window tinting.

Any replacement glass fitted to a motor vehicle, including an interior partition, must be of appropriate automotive safety glass or other approved material and must comply with the Standards.

Some manufacturers incorporate the windscreen and rear window into the structural design of the vehicle and if improperly secured may reduce the crash worthiness of the vehicle.

Vehicle glazing must comply with the same characteristics as material mentioned in any of the following standards:

• AS208, ECE R43/00, BS AU178, JIS R 3211, AN Z26.1 or NZS 5443.
• The windscreen glass must carry the indelible mark or marks of the relevant standards. These must be visible when the windscreen is fitted in the vehicle, and the marking must identify the type of glass and the relevant standard to which the glass conforms.
• All replacement transparent material must be of a type that will not shatter.
• The windscreen must be free from scratches, cracks or chips.

Related information

Other websites

• Australian Design Rules

Legislation

• Road Traffic (Light Vehicle Standards) Rules 2018

Vehicle Standards reference: see also PDF MR1457.