The DVSA has released the 2025 updates to the HGV and PSV Inspection Manual, and every operator needs to understand what has changed. These updates affect safety inspections, defect standards, and how vehicles are assessed during roadside and annual checks.
This guide breaks down the key changes in simple language and explains what operators must do now to stay compliant. Blue Flag Transport Consulting provides expert insight to help you adjust your systems before issues appear at a DVSA check or MOT.
Why the 2025 Manual Update Matters
The inspection manual sets the standards DVSA uses when examining HGVs and PSVs. Any change affects how defects are judged and what counts as a failure.
Failing to follow the updated guidance can lead to:
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Prohibitions at roadside checks
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Increased MOT failures
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Poor OCRS scores
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Risk of regulatory action
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Potential Public Inquiry
Operators who update their systems early avoid these problems and protect their Operator Licence.
Key Changes in the 2025 HGV and PSV Inspection Manual
1. Clearer Standards for Brake Performance
The 2025 update places more focus on brake testing frequency and the quality of brake performance records.
What’s new:
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Stricter guidance for when a full roller brake test is required.
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Updated thresholds for imbalance and efficiency.
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More emphasis on consistent brake testing throughout the year.
What operators must do:
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Ensure every vehicle gets meaningful brake tests at regular intervals.
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Review test reports for trends or repeated issues.
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Store clear, accurate brake performance records.
2. Updated Rules on Tyres and Wheel Fixings
Tyre inspections now include more detailed criteria for identifying unsafe wear patterns and sidewall damage.
Key updates:
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New wording on dangerous tread separation.
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Clearer rules around age limits, especially for passenger vehicles.
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Extra attention on cracked rims and loose fixings.
Action for operators:
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Train drivers on improved tyre defect recognition.
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Audit your tyre management policy.
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Remove any tyre showing early signs of structural damage.
3. Revised Lighting and Electrical System Checks
Lighting faults remain one of the most common roadside failures. The 2025 manual reinforces this area.
Changes include:
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Updated checks on LED systems.
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More detail on insecure wiring and damaged connectors.
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Stricter criteria for daytime running lights (DRLs) where fitted.
Operator priority:
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Add electrical checks to walk-around inspections.
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Ensure repairs are completed before the vehicle is used.
4. Load Security Guidance Strengthened
Load security issues continue to cause major enforcement action. The 2025 update clarifies how DVSA will assess different load types.
Highlights:
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More detailed examples of acceptable restraint.
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Updated guidance on curtain-sided vehicles.
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Clearer requirements for mixed loads.
What operators must do:
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Review load security training for drivers.
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Update internal load security policies.
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Carry out spot checks on your fleet.
5. Steering and Suspension Checks Expanded
The manual now includes more precise criteria for steering play, worn components, and suspension defects.
Updates:
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Better definitions of “excess wear.”
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New defect categories for air suspension leaks.
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Clearer fail points for track rod ends and ball joints.
Operator focus:
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Ensure maintenance teams follow the latest inspection sequence.
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Replace worn parts early to avoid prohibitions.
6. Emissions and Exhaust System Checks Tightened
The push for cleaner vehicles continues in 2025. DVSA inspectors now apply tighter limits during emissions checks.
Changes include:
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Updated diesel smoke test guidance.
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Stricter fault categories for exhaust leaks.
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Extra focus on tampered emission-control systems.
Operator task:
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Make sure vehicles receive regular emissions health checks.
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Never ignore engine management warning lights.
7. Record-Keeping Expectations Strengthened
DVSA now expects operators to hold clearer records, particularly around repeat defects and maintenance scheduling.
What’s changed:
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New guidance on minimum record detail.
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Stronger expectations for digital or well-organised paper systems.
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More emphasis on tracking repeated issues.
Operator requirement:
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Ensure all records are complete, legible, and easy to find.
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Move to digital systems where possible.
What Operators Should Do Now
To stay compliant, operators must adjust their systems to match the 2025 manual.
Immediate steps:
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Review your maintenance system against the updated manual.
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Update driver walk-around check forms.
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Train drivers and maintenance staff on new standards.
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Carry out internal compliance audits.
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Replace outdated inspection templates.
Blue Flag Transport Consulting can complete a full compliance review to check whether your maintenance and inspection systems reflect the 2025 changes.
How Blue Flag Transport Consulting Supports Operators
Blue Flag provides expert assistance to help operators adapt to the 2025 updates:
Their support includes:
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Full maintenance system audits
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Updated inspection templates and checklists
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Driver and maintenance team training
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Brake testing strategy reviews
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Load security compliance advice
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Record-keeping system improvements
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Ongoing compliance monitoring
This ensures your fleet meets DVSA expectations and reduces the risk of MOT failures or enforcement action.
The 2025 Inspection Manual brings important updates that every operator must understand. By reviewing your systems, training staff, and strengthening maintenance controls, you can stay compliant, protect your Operator Licence, and improve road safety across your fleet.
With support from Blue Flag Transport Consulting, operators can adjust quickly and confidently to the new standards.
Contact Blue Flag Transport Consulting Today
Need help preparing for the 2025 inspection changes? Visit Blue Flag Transport Consulting for expert audits, updated checklists, and compliance guidance tailored to your fleet.
