Repairing written-off vehicles

A crash repair diary is a detailed record explaining what repairs were needed on the vehicle, what repair techniques were referenced and how they were applied during the repair. It also contains progress photographs and other material to provide evidence of the nature, extent and activities of the vehicle repair.

When taking photos, it is best to take a number of photos to ensure you describe the process properly. When dismantling a vehicle, take photos, when components are being fitted or being repaired and refitted, take photos.

Depending on the repair area, and how close the photo is taken, it may be difficult in interpreting what part of the vehicle the photo is showing. In these cases it is best to take a photo from a medium distance, and then a close up. Sometimes it helps when scale is introduced to the photo, so a tape measure can be pictured against the subject area to assist.

When compiling the crash repair diary, each step should be documented with photos and cross referenced with the relevant area from the manufacturer’s guidelines. A recommended outline of the crash repair diary may contain description and photos

• before repair work
• during jigging
• removed panels and pieces
• replacement panels and pieces
• method of attachment of replacement panels and pieces.

Keeping a crash repair diary when repairing a vehicle creates visibility of the repair process and you will be less likely to encounter difficulty when presenting the vehicle for a VIV inspection.  If the crash repair diary is done correctly, you may reduce the likelihood of the vehicle being requested to undergo further inspections. For example a ‘Vehicle Damage and Structural Repair Report’ may not be required if the crash repair diary sufficiently documents the process of repair.

Generally, a fire damaged vehicle will be assessed as a Statutory Write-Off. In the case where the fire damage is minor and the vehicle is assessed as a repairable write-off, the fire damaged components must be replaced. It should be understood that the heat in the incident may not be limited to the immediate fire area, and have affected other components in the vehicle, especially high strength light alloy steels in key structural components. Repairing such a vehicle may facilitate replacement of major components that have been heat affected, and may become more costly than estimated.

If using components from a fire damaged vehicle to repair another vehicle, heat affected components from the damaged vehicle cannot be used. Doing so may compromise the structural integrity of the vehicle. Photographic evidence of the donor car (in this case the fire damaged vehicle) should be supplied to verify the extent of damage to the vehicle.

A vehicle that is immersed in fresh, salt and/or brackish water to the extent that the internal cabin water level rises above the level of the inner door sill for any period will be assessed as a statutory write-off. If there is evidence at a VIV inspection indicating that a vehicle has been immersed to this extent, the vehicle will fail the VIV inspection and is not eligible for registration in Victoria. Very limited components from water immersed vehicles may be used to repair other vehicles, given the likelihood of corrosion and lack of future serviceability.

If a vehicle has been water immersed and was assessed as a repairable write-off, as part of the VIV inspection you will be required to obtain a Supplementary Restraint System (SRS) / Electronic Control Unit (ECU) report from an authorised dealer of the manufacturer. This report certifies that the ECU has been checked for contamination and / or replaced and all wiring links have been checked for contamination. The dealer is required to confirm that all integrated circuitry (ABS, Traction Control, Stability Control etc) are not compromised and the air bags and any seat belt pre-tensioners are not contaminated and are still serviceable.

If the ECU or other components are found to be contaminated, the dealer may require a replacement ECU to be fitted before the report is issued. A new or second hand ECU may be used. However, if utilising a second hand ECU the component must not be refurbished from another water damaged vehicle, and donor VIN details are required to be provided to the VIV Inspector.

The SRS report is not a simple SRS diagnostic check. The cost to obtain this report should be noted, as there is a significant labour component for a dealer of the manufacturer to undertake this work. If contamination is identified, this will result in further costs in replacing the affected components.

If there is evidence that a dealer has not performed the correct checks, or is not in the regular business of servicing that vehicle category (for example a truck / commercial dealer cannot issue such a report for a standard passenger vehicle), you may be requested to obtain another report, or obtain further information regarding the service provided.

You may obtain the report prior to the VIV Inspection, provided the Supplementary Support System Report [PDF 122 Kb] form is fully completed and stamped by an authorised dealer of the manufacturer, and is accompanied by a tax invoice.

While the vehicle may function correctly on the day of the VIV inspection and when the SRS report is obtain, it cannot be guaranteed the vehicle will remain serviceable in future. It is the responsibility of the owner/operator to ensure the ongoing roadworthiness of the vehicle.

If a vehicle has been entered on the WOVR due to water immersion, the following table illustrates whether its components can be used to repair another vehicle.

On occasion, a vehicle may be entered on the WOVR as a repairable write-off and bear only cosmetic damage which does not compromise the vehicle’s crashworthiness or vehicle safety systems.

The Road Safety (Vehicles) Regulations 2009 requires that the damage which caused the vehicle to be entered on the WOVR as a repairable write-off, must be repaired, restored or replaced. Accordingly, cosmetically damage vehicles (for example a motorcycle with scratched fairings or a vehicle with paint damage) must be repaired, restored or replaced in order to pass the VIV inspection.

This requirement is consistent with the objectives of the Written-Off Vehicles Register.

VicRoads guidelines for a fuel contaminated vehicle require at a minimum, its components to be replaced with the following.

• Replacement catalytic converter(s) with original receipt.
• New original vehicle manufacturer oxygen sensor(s) with original receipt. A second hand or after market oxygen sensor cannot be used.
• New original vehicle manufacturer carbon / charcoal canister. A second hand or after market carbon / charcoal canister cannot be used.
• An original itemised receipt from an authorised dealer of the vehicle manufacturer confirming an engine diagnostic check (to confirm that the engine management systems are still functioning) has been completed and no error codes or problems are identified.

The outcome of the engine diagnostic check may necessitate replacement of the fuel injector, fuel pump, fuel filter/s, fuel tank, fuel lines (or the fuel system in its entirety).

The catalytic converter may be replaced / repaired in the following ways:

• with original equipment (OE) manufacturer parts, or
• with aftermarket parts provided there is a certification by the manufacturer or supplier that the parts perform to a standard equivalent to a OE part, or
• with second-hand parts, provided a test certificate is provided to show that the vehicle has successfully passed one of the following emission tests.  Details of donor VIN’s will be required for vehicles repaired with second-hand parts.  The second-hand parts must also not be from a vehicle recorded as fuel contaminated on the WOVR.

In respect of testing catalytic converters, the EPA Victoria has advised that there are two alternatives for testing second-hand components to confirm that the catalytic converters are functioning.

1. Use of pyrometer (infra-red thermal measurement equipment): Measure the temperature prior to the catalyst, on the catalyst and after the catalyst.  A functioning catalytic converter will have a distinctly higher temperature on and after the converter than before.  Care must be taken to ensure the thermal measurement is taken on the skin of the pipe or converter, not on the heat shields.
2. Use of a carbon monoxide (CO/hydrocarbon (HC)) garage type gas analyser.  Measure the levels of CO and HC at idle.  Bring the engine speed to a high idle (eg 2500 rev/min).  After a short period, the levels of CO and HC should decrease.

These tests are available from EPA Victoria approved vehicle emissions testers. In both cases, the vehicle should be at normal operating temperature.

Test certificates can only be provided by an EPA approved vehicle emissions systems tester.

Please visit the Vehicles damage by hail storms page for more information.

When engaging a repairer to repair a vehicle or when parts are purchased for a vehicle, it is expected that a valid tax invoice, as prescribed by the Australian Tax Office, is issued for the parts and / or labour to repair the vehicle. You are required to retain and present all tax invoices at the time of VIV inspection to verify the legitimacy of the repair.

When second hand components (including second hand imported parts) are used to repair the vehicle, the tax invoice will need to provide the vehicle identification number (VIN) of the vehicle(s) from which the parts were sourced. If no donor VIN details are provided, you will encounter difficulty during the inspection process.

Adequate documentation in relation to the origin/source of vehicle components is required to ensure:

• the replacement part is suitable for the particular make/model of vehicle
• that the part has not come from a water immersed or fire damaged vehicle, or a vehicle that has been damaged in the area where the part has come from.

If you bought the vehicle in a repaired condition, be aware that you are still required to obtain the required documents and tax invoices from the previous owner where possible, and provide a statutory declaration to this effect.

If appropriate documentation cannot be provided or is considered suspect, the vehicle may fail the inspection.