| # | Inspection Item | OK | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 |
Tires - Pressure, Tread & ConditionCRITICAL
Check all tires incl. spare. Tread depth ≥ 2/32". No bulges,
cuts, embedded objects. Verify pressure per door sticker.
|
||||
| 2 |
Engine Oil Level & Condition
Dipstick between MIN–MAX. Colour should be amber/brown. Dark
gritty = overdue change. Log mileage since last change.
|
||||
| 3 |
Coolant Level
Check overflow reservoir cold. Between MIN–MAX. No leaks under
vehicle. Never open radiator cap when hot.
|
||||
| 4 |
Brake Fluid & Power Steering Fluid
Both reservoirs at correct level. Low brake fluid = possible
pad wear or line leak. Check for discolouration.
|
||||
| 5 |
Windshield Washer Fluid & DEF (Diesel)
Top up washer fluid. For diesel vehicles: check DEF/AdBlue
level - low DEF triggers engine derate.
|
||||
| 6 |
Fuel Level
Confirm sufficient fuel for planned route. Log fuel level and
fuel card usage if applicable.
|
||||
| 7 |
All Lights & ReflectorsCRITICAL
Headlights (low/high), taillights, brake lights, turn signals,
hazard flashers, reverse lights, clearance/marker lights,
reflectors.
|
||||
| 8 |
Windshield, Wipers & Mirrors
No cracks/chips obstructing view. Wipers clear without
streaking. All mirrors clean, adjusted, and secure.
|
||||
| 9 |
Brakes - Pedal Feel & Parking BrakeCRITICAL
Firm pedal, no spongy feel, no pulling. Parking brake holds on
incline. Listen for grinding/squealing at low speed.
|
||||
| 10 |
Steering Response
No excessive play (<2" free play on steering wheel). No
unusual noises when turning. Smooth return to centre.
|
||||
| 11 |
Horn, Seatbelts & Cabin Safety
Horn audible. All seatbelts latch, retract, and lock on pull.
Seats secure. No loose objects in cabin.
|
||||
| 12 |
Dashboard Warnings & Gauges
No active warning lights (CEL, ABS, airbag, oil, temp). All
gauges in normal range after ignition.
|
||||
| 13 |
Emergency EquipmentCRITICAL
Fire extinguisher charged & accessible. First aid kit stocked.
Warning triangles/flares present. Reflective vest available.
|
||||
| 14 |
Walk-Around: Body, Undercarriage & Cargo
No new dents/damage. No fluid puddles under vehicle. All
doors/latches work. Cargo secured, load within GVWR.
|
| # | Inspection Item | OK | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 |
Belts - Serpentine, Timing & A/C
Check tension, cracking, fraying, glazing. Replace if cracks
per inch exceed OEM limit.
|
||||
| 2 |
Hoses - Coolant, Heater & Vacuum
Squeeze-test for softness/hardness. Look for bulges, wet
spots, loose clamps. Replace if swollen.
|
||||
| 3 |
Battery Health & Terminals
Load test (≥12.4V resting, ≥9.6V under load). Clean corrosion
from terminals. Check cable tightness.
|
||||
| 4 |
Brake Pads/Shoes & Rotors/DrumsCRITICAL
Pad thickness ≥ 3mm (replace if less). Rotors: no scoring
deeper than 1.5mm, no heat spots, no warping.
|
||||
| 5 |
Transmission Fluid - Level & Quality
Dipstick level correct. Colour: bright red (ATF) or clear
(CVT). Dark/burnt smell = schedule fluid change.
|
||||
| 6 |
Coolant Quality & Concentration
Test with refractometer (freeze point ≤ -34°C / -29°F). No
rust, sludge, or oil contamination.
|
||||
| 7 |
Suspension - Shocks, Struts & Bushings
Bounce test: vehicle settles in 1–2 bounces. No fluid leaks on
shocks. Bushings not cracked or perished.
|
||||
| 8 |
Air Filter & Cabin Filter
Hold engine air filter to light - replace if light doesn't
pass through. Replace cabin filter if visibly dirty.
|
||||
| 9 |
Exhaust System & Muffler
Look for rust holes, loose hangers, exhaust leaks (soot stains
at joints). Check catalytic converter brackets.
|
||||
| 10 |
HVAC, A/C & Defroster
Test all modes: heat, A/C, defrost. Confirm adequate airflow.
Weak A/C = check refrigerant charge.
|
||||
| 11 |
Lug Nut Torque & Wheel Condition
Re-torque all lug nuts to OEM spec with calibrated torque
wrench. Check for cracked or bent wheels.
|
| # | Inspection Item | OK | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 |
Tire Rotation & Alignment Check
Rotate per OEM pattern. Check alignment: no pull, no uneven
shoulder wear. Record tread depths (32nds).
|
||||
| 2 |
Brake Lines, Calipers & Wheel Cylinders
Inspect hard lines for rust/corrosion, flex lines for
cracking. Check caliper slides, bleeder valves. No fluid weep.
|
||||
| 3 |
Steering Linkage & Components
Check tie rod ends, ball joints, idler arm, pitman arm for
play. Boots intact, no grease leaks.
|
||||
| 4 |
All Fluid Analysis (Oil, Trans, Coolant, Diff)
Sample and lab-test all fluids. Look for metal content, water
intrusion, acidity. Compare to baseline values.
|
||||
| 5 |
Electrical System & Alternator Output
Alternator output 13.5–14.8V at idle. Test all fuses. Verify
ground connections. Check wiring for chafe/rub.
|
||||
| 6 |
Fuel System - Filter, Lines & Tank
Replace fuel filter per OEM interval. Check fuel lines for
cracks/leaks. Inspect tank straps and cap seal.
|
||||
| 7 |
Telematics, GPS & Dash Cam Function
Confirm GPS tracking is live. Dash cam records and uploads.
OBD-II device connected. No fault codes masked.
|
||||
| 8 |
Breakdown & Downtime Log Review
Review last 90 days of breakdown records. Identify repeat
failures. Adjust PM intervals if patterns emerge.
|
| # | Inspection Item | OK | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 |
Regulatory Safety InspectionCRITICAL
DOT/FMCSA annual (US) · MoRTH fitness cert (India) · DVSA MOT
(UK) · TÜV (EU). File certificate.
|
||||
| 2 |
Emissions & Pollution CertificationCRITICAL
Smog test (US) · PUC certificate (India) · MOT emissions
(UK/EU). Check EGR valve, O₂ sensors, DPF condition.
|
||||
| 3 |
Engine Mounts & Drivetrain
Motor mounts: no cracks, excessive movement. U-joints, CV
axles, driveshaft balance, differential play within spec.
|
||||
| 4 |
Full Cooling System Flush
Drain, chemical flush, refill with OEM coolant. Replace
thermostat if due. Pressure test system for leaks.
|
||||
| 5 |
Transmission Fluid & Filter Change
Full ATF/CVT drain and refill. Replace transmission filter.
Pan inspection for metal shavings. (OEM: 50k–80k km).
|
||||
| 6 |
Differential Fluid Replacement
Drain front and rear diff fluid. Inspect drain plug magnet for
metal shavings (gear wear indicator). Refill per OEM spec.
|
||||
| 7 |
Complete Brake System Overhaul
Full brake fluid flush (DOT 3/4). Inspect all lines, calipers,
wheel cylinders, ABS sensors. Replace worn components.
|
||||
| 8 |
Fuel Injection System Service
Ultrasonic or chemical cleaning of injectors, throttle body,
intake valves. Measure and record fuel pressure.
|
||||
| 9 |
Frame, Chassis & Structural Integrity
Inspect for corrosion, cracks, weld failures. Check
crossmembers, subframe, body mounts. Apply rust protection if
needed.
|
||||
| 10 |
Safety Equipment Certification
Fire extinguisher: in-date & tagged. First aid kit: restocked
per regulation. Warning triangles, reflective vests, wheel
chocks present.
|
||||
| 11 |
Insurance, Registration, Permits & DocsCRITICAL
Vehicle insurance valid. Registration renewed. Fleet permits,
fitness certificates, route permits current. Copies in
vehicle.
|
© 2026 FleetFlow by Hyvikk Solutions
Free resource from:
"The Ultimate Preventive Fleet Maintenance Checklist"
General guidance only. Always follow your vehicle OEM manual for
exact service intervals and torque specs.