backend/src/core/config/config-loader.ts

@@ -41,14 +41,6 @@ const configSchema = z.object({
     audience: z.string(),
   }),
 
-  // External APIs configuration (optional)
-  external: z.object({
-    vpic: z.object({
-      url: z.string(),
-      timeout: z.string(),
-    }).optional(),
-  }).optional(),
-
   // Service configuration
   service: z.object({
     name: z.string(),

backend/src/core/config/feature-tiers.ts

@@ -29,7 +29,7 @@ export const FEATURE_TIERS: Record<string, FeatureConfig> = {
   'vehicle.vinDecode': {
     minTier: 'pro',
     name: 'VIN Decode',
-    upgradePrompt: 'Upgrade to Pro to automatically decode VIN and populate vehicle details from the NHTSA database.',
+    upgradePrompt: 'Upgrade to Pro to automatically decode VIN and populate vehicle details from the vehicle database.',
   },
   'fuelLog.receiptScan': {
     minTier: 'pro',

backend/src/features/ocr/CLAUDE.md

@@ -37,7 +37,7 @@ Backend proxy for the Python OCR microservice. Handles authentication, tier gati
 
 | File | What | When to read |
 | ---- | ---- | ------------ |
-| `ocr-client.ts` | HTTP client to mvp-ocr Python service (extract, extractVin, extractReceipt, submitJob, submitManualJob, getJobStatus, isHealthy) | OCR service communication, error handling |
+| `ocr-client.ts` | HTTP client to mvp-ocr Python service (extract, extractVin, extractReceipt, decodeVin, submitJob, submitManualJob, getJobStatus, isHealthy) | OCR service communication, error handling |
 
 ## tests/
 

backend/src/features/ocr/domain/ocr.types.ts

@@ -131,3 +131,21 @@ export interface ManualJobResponse {
   result?: ManualExtractionResult;
   error?: string;
 }
+
+/** Response from VIN decode via Gemini (OCR service) */
+export interface VinDecodeResponse {
+  success: boolean;
+  vin: string;
+  year: number | null;
+  make: string | null;
+  model: string | null;
+  trimLevel: string | null;
+  bodyType: string | null;
+  driveType: string | null;
+  fuelType: string | null;
+  engine: string | null;
+  transmission: string | null;
+  confidence: number;
+  processingTimeMs: number;
+  error: string | null;
+}

backend/src/features/ocr/external/ocr-client.ts

@@ -2,7 +2,7 @@
  * @ai-summary HTTP client for OCR service communication
  */
 import { logger } from '../../../core/logging/logger';
-import type { JobResponse, ManualJobResponse, OcrResponse, ReceiptExtractionResponse, VinExtractionResponse } from '../domain/ocr.types';
+import type { JobResponse, ManualJobResponse, OcrResponse, ReceiptExtractionResponse, VinDecodeResponse, VinExtractionResponse } from '../domain/ocr.types';
 
 /** OCR service configuration */
 const OCR_SERVICE_URL = process.env.OCR_SERVICE_URL || 'http://mvp-ocr:8000';
@@ -373,6 +373,55 @@ export class OcrClient {
     return result;
   }
 
+  /**
+   * Decode a VIN string into structured vehicle data via Gemini.
+   *
+   * Unlike other OCR methods, this sends JSON (not multipart) because
+   * VIN decode has no file upload.
+   *
+   * @param vin - 17-character Vehicle Identification Number
+   * @returns Structured vehicle data from Gemini decode
+   */
+  async decodeVin(vin: string): Promise<VinDecodeResponse> {
+    const url = `${this.baseUrl}/decode/vin`;
+
+    logger.info('OCR VIN decode request', {
+      operation: 'ocr.client.decodeVin',
+      url,
+      vin,
+    });
+
+    const response = await this.fetchWithTimeout(url, {
+      method: 'POST',
+      headers: { 'Content-Type': 'application/json' },
+      body: JSON.stringify({ vin }),
+    });
+
+    if (!response.ok) {
+      const errorText = await response.text();
+      logger.error('OCR VIN decode failed', {
+        operation: 'ocr.client.decodeVin.error',
+        status: response.status,
+        error: errorText,
+      });
+      const err: any = new Error(`OCR service error: ${response.status} - ${errorText}`);
+      err.statusCode = response.status;
+      throw err;
+    }
+
+    const result = (await response.json()) as VinDecodeResponse;
+
+    logger.info('OCR VIN decode completed', {
+      operation: 'ocr.client.decodeVin.success',
+      success: result.success,
+      vin: result.vin,
+      confidence: result.confidence,
+      processingTimeMs: result.processingTimeMs,
+    });
+
+    return result;
+  }
+
   /**
    * Check if the OCR service is healthy.
    *

backend/src/features/platform/README.md

@@ -117,7 +117,7 @@ platform/
 When implemented, VIN decoding will use:
 1. **Cache First**: Check Redis (7-day TTL for success, 1-hour for failures)
 2. **PostgreSQL**: Database function for high-confidence decode
-3. **vPIC Fallback**: NHTSA vPIC API with circuit breaker protection
+3. **OCR Service Fallback**: Gemini VIN decode via OCR service
 4. **Graceful Degradation**: Return meaningful errors when all sources fail
 
 ### Database Schema
@@ -164,7 +164,7 @@ When VIN decoding is implemented:
 
 ### External APIs (Planned/Future)
 When VIN decoding is implemented:
-- **NHTSA vPIC**: https://vpic.nhtsa.dot.gov/api (VIN decoding fallback)
+- **OCR Service**: Gemini VIN decode via mvp-ocr (VIN decoding fallback)
 
 ### Database Tables
 - **vehicle_options** - Hierarchical vehicle data (years, makes, models, trims, engines, transmissions)
@@ -269,7 +269,7 @@ npm run lint
 ## Future Considerations
 
 ### Planned Features
-- VIN decoding endpoint with PostgreSQL + vPIC fallback
+- VIN decoding endpoint with PostgreSQL + Gemini/OCR service fallback
 - Circuit breaker pattern for external API resilience
 
 ### Potential Enhancements

backend/src/features/platform/models/responses.ts

@@ -61,19 +61,3 @@ export interface VINDecodeResponse {
   error?: string;
 }
 
-/**
- * vPIC API response structure (NHTSA)
- */
-export interface VPICVariable {
-  Variable: string;
-  Value: string | null;
-  ValueId: string | null;
-  VariableId: number;
-}
-
-export interface VPICResponse {
-  Count: number;
-  Message: string;
-  SearchCriteria: string;
-  Results: VPICVariable[];
-}

backend/src/features/vehicles/CLAUDE.md

@@ -16,6 +16,6 @@
 | `data/` | Repository, database queries | Database operations |
 | `docs/` | Feature-specific documentation | Vehicle design details |
 | `events/` | Event handlers and emitters | Cross-feature event integration |
-| `external/` | External service integrations (NHTSA) | VIN decoding, third-party APIs |
+| `external/` | External service integrations | VIN decoding, third-party APIs |
 | `migrations/` | Database schema | Schema changes |
 | `tests/` | Unit and integration tests | Adding or modifying tests |

backend/src/features/vehicles/README.md

@@ -13,7 +13,7 @@ Primary entity for vehicle management consuming MVP Platform Vehicles Service. H
 - `DELETE /api/vehicles/:id` - Soft delete vehicle
 
 ### VIN Decoding (Pro/Enterprise Only)
-- `POST /api/vehicles/decode-vin` - Decode VIN using NHTSA vPIC API
+- `POST /api/vehicles/decode-vin` - Decode VIN using Gemini via OCR service
 
 ### Hierarchical Vehicle Dropdowns
 **Status**: Vehicles service now proxies the platform vehicle catalog to provide fully dynamic dropdowns. Each selection step filters the next list, ensuring only valid combinations are shown.
@@ -104,11 +104,7 @@ vehicles/
 ├── data/                  # Database layer
 │   └── vehicles.repository.ts
 ├── external/              # External service integrations
-│   ├── CLAUDE.md          # Integration pattern docs
-│   └── nhtsa/             # NHTSA vPIC API client
-│       ├── nhtsa.client.ts
-│       ├── nhtsa.types.ts
-│       └── index.ts
+│   └── CLAUDE.md          # Integration pattern docs
 ├── migrations/            # Feature schema
 │   └── 001_create_vehicles_tables.sql
 ├── tests/                 # All tests
@@ -121,14 +117,14 @@ vehicles/
 
 ## Key Features
 
-### 🔍 VIN Decoding (NHTSA vPIC API)
+### VIN Decoding (Gemini via OCR Service)
 - **Tier Gating**: Pro and Enterprise users only (`vehicle.vinDecode` feature key)
-- **NHTSA API**: Calls official NHTSA vPIC API for authoritative vehicle data
+- **Gemini**: Calls OCR service Gemini VIN decode for authoritative vehicle data
 - **Caching**: Results cached in `vin_cache` table (1-year TTL, VIN data is static)
 - **Validation**: 17-character VIN format, excludes I/O/Q characters
 - **Matching**: Case-insensitive exact match against dropdown options
 - **Confidence Levels**: High (exact match), Medium (normalized match), None (hint only)
-- **Timeout**: 5-second timeout for NHTSA API calls
+- **Timeout**: 5-second timeout for OCR service calls
 
 #### Decode VIN Request
 ```json
@@ -140,15 +136,15 @@ Authorization: Bearer <jwt>
 
 Response (200):
 {
-  "year": { "value": 2021, "nhtsaValue": "2021", "confidence": "high" },
-  "make": { "value": "Honda", "nhtsaValue": "HONDA", "confidence": "high" },
-  "model": { "value": "Civic", "nhtsaValue": "Civic", "confidence": "high" },
-  "trimLevel": { "value": "EX", "nhtsaValue": "EX", "confidence": "high" },
-  "engine": { "value": null, "nhtsaValue": "2.0L L4 DOHC 16V", "confidence": "none" },
-  "transmission": { "value": null, "nhtsaValue": "CVT", "confidence": "none" },
-  "bodyType": { "value": null, "nhtsaValue": "Sedan", "confidence": "none" },
-  "driveType": { "value": null, "nhtsaValue": "FWD", "confidence": "none" },
-  "fuelType": { "value": null, "nhtsaValue": "Gasoline", "confidence": "none" }
+  "year": { "value": 2021, "decodedValue": "2021", "confidence": "high" },
+  "make": { "value": "Honda", "decodedValue": "HONDA", "confidence": "high" },
+  "model": { "value": "Civic", "decodedValue": "Civic", "confidence": "high" },
+  "trimLevel": { "value": "EX", "decodedValue": "EX", "confidence": "high" },
+  "engine": { "value": null, "decodedValue": "2.0L L4 DOHC 16V", "confidence": "none" },
+  "transmission": { "value": null, "decodedValue": "CVT", "confidence": "none" },
+  "bodyType": { "value": null, "decodedValue": "Sedan", "confidence": "none" },
+  "driveType": { "value": null, "decodedValue": "FWD", "confidence": "none" },
+  "fuelType": { "value": null, "decodedValue": "Gasoline", "confidence": "none" }
 }
 
 Error (400 - Invalid VIN):
@@ -157,7 +153,7 @@ Error (400 - Invalid VIN):
 Error (403 - Tier Required):
 { "error": "TIER_REQUIRED", "requiredTier": "pro", "currentTier": "free", ... }
 
-Error (502 - NHTSA Failure):
+Error (502 - OCR Service Failure):
 { "error": "VIN_DECODE_FAILED", "message": "Unable to decode VIN from external service" }
 ```
 
@@ -230,7 +226,7 @@ Error (502 - NHTSA Failure):
 ## Testing
 
 ### Unit Tests
-- `vehicles.service.test.ts` - Business logic with mocked dependencies (VIN decode, caching, CRUD operations)
+- `vehicles.service.test.ts` - Business logic with mocked dependencies (VIN decode via OCR service mock, caching, CRUD operations)
 
 ### Integration Tests
 - `vehicles.integration.test.ts` - Complete API workflow with test database (create, read, update, delete vehicles)

backend/src/features/vehicles/api/vehicles.controller.ts

@@ -10,19 +10,18 @@ import { pool } from '../../../core/config/database';
 import { logger } from '../../../core/logging/logger';
 import { CreateVehicleBody, UpdateVehicleBody, VehicleParams } from '../domain/vehicles.types';
 import { getStorageService } from '../../../core/storage/storage.service';
-import { NHTSAClient, DecodeVinRequest } from '../external/nhtsa';
+import { ocrClient } from '../../ocr/external/ocr-client';
+import type { DecodeVinRequest } from '../domain/vehicles.types';
 import crypto from 'crypto';
 import FileType from 'file-type';
 import path from 'path';
 
 export class VehiclesController {
   private vehiclesService: VehiclesService;
-  private nhtsaClient: NHTSAClient;
 
   constructor() {
     const repository = new VehiclesRepository(pool);
     this.vehiclesService = new VehiclesService(repository, pool);
-    this.nhtsaClient = new NHTSAClient(pool);
   }
 
   async getUserVehicles(request: FastifyRequest, reply: FastifyReply) {
@@ -378,7 +377,7 @@ export class VehiclesController {
   }
 
   /**
-   * Decode VIN using NHTSA vPIC API
+   * Decode VIN using OCR service (Gemini)
    * POST /api/vehicles/decode-vin
    * Requires Pro or Enterprise tier
    */
@@ -395,13 +394,34 @@ export class VehiclesController {
         });
       }
 
-      logger.info('VIN decode requested', { userId, vin: vin.substring(0, 6) + '...' });
+      // Validate VIN format
+      const sanitizedVin = vin.trim().toUpperCase();
+      const VIN_REGEX = /^[A-HJ-NPR-Z0-9]{17}$/;
+      if (!VIN_REGEX.test(sanitizedVin)) {
+        return reply.code(400).send({
+          error: 'INVALID_VIN',
+          message: 'Invalid VIN format. VIN must be exactly 17 characters and contain only letters (except I, O, Q) and numbers.'
+        });
+      }
 
-      // Validate and decode VIN
-      const response = await this.nhtsaClient.decodeVin(vin);
+      logger.info('VIN decode requested', { userId, vin: sanitizedVin.substring(0, 6) + '...' });
 
-      // Extract and map fields from NHTSA response
-      const decodedData = await this.vehiclesService.mapNHTSAResponse(response);
+      // Check cache first
+      const cached = await this.vehiclesService.getVinCached(sanitizedVin);
+      if (cached) {
+        logger.info('VIN decode cache hit', { userId });
+        const decodedData = await this.vehiclesService.mapVinDecodeResponse(cached);
+        return reply.code(200).send(decodedData);
+      }
+
+      // Call OCR service for VIN decode
+      const response = await ocrClient.decodeVin(sanitizedVin);
+
+      // Cache the response
+      await this.vehiclesService.saveVinCache(sanitizedVin, response);
+
+      // Map response to decoded vehicle data with dropdown matching
+      const decodedData = await this.vehiclesService.mapVinDecodeResponse(response);
 
       logger.info('VIN decode successful', {
         userId,
@@ -414,7 +434,7 @@ export class VehiclesController {
     } catch (error: any) {
       logger.error('VIN decode failed', { error, userId });
 
-      // Handle validation errors
+      // Handle VIN validation errors
       if (error.message?.includes('Invalid VIN')) {
         return reply.code(400).send({
           error: 'INVALID_VIN',
@@ -422,16 +442,25 @@ export class VehiclesController {
         });
       }
 
-      // Handle timeout
-      if (error.message?.includes('timed out')) {
-        return reply.code(504).send({
-          error: 'VIN_DECODE_TIMEOUT',
-          message: 'NHTSA API request timed out. Please try again.'
+      // Handle OCR service errors by status code
+      if (error.statusCode === 503 || error.statusCode === 422) {
+        return reply.code(502).send({
+          error: 'VIN_DECODE_FAILED',
+          message: 'VIN decode service unavailable',
+          details: error.message
         });
       }
 
-      // Handle NHTSA API errors
-      if (error.message?.includes('NHTSA')) {
+      // Handle timeout
+      if (error.message?.includes('timed out') || error.message?.includes('aborted')) {
+        return reply.code(504).send({
+          error: 'VIN_DECODE_TIMEOUT',
+          message: 'VIN decode service timed out. Please try again.'
+        });
+      }
+
+      // Handle OCR service errors
+      if (error.message?.includes('OCR service error')) {
         return reply.code(502).send({
           error: 'VIN_DECODE_FAILED',
           message: 'Unable to decode VIN from external service',

backend/src/features/vehicles/api/vehicles.routes.ts

@@ -75,7 +75,7 @@ export const vehiclesRoutes: FastifyPluginAsync = async (
     handler: vehiclesController.getDropdownOptions.bind(vehiclesController)
   });
 
-  // POST /api/vehicles/decode-vin - Decode VIN using NHTSA vPIC API (Pro/Enterprise only)
+  // POST /api/vehicles/decode-vin - Decode VIN via OCR service (Pro/Enterprise only)
   fastify.post<{ Body: { vin: string } }>('/vehicles/decode-vin', {
     preHandler: [fastify.authenticate, fastify.requireTier({ featureKey: 'vehicle.vinDecode' })],
     handler: vehiclesController.decodeVin.bind(vehiclesController)

backend/src/features/vehicles/domain/vehicles.service.ts

@@ -24,7 +24,8 @@ import { isValidVIN, isValidPreModernVIN } from '../../../shared-minimal/utils/v
 import { normalizeMakeName, normalizeModelName } from './name-normalizer';
 import { getVehicleDataService, getPool } from '../../platform';
 import { auditLogService } from '../../audit-log';
-import { NHTSAClient, NHTSADecodeResponse, DecodedVehicleData, MatchedField } from '../external/nhtsa';
+import type { VinDecodeResponse } from '../../ocr/domain/ocr.types';
+import type { DecodedVehicleData, MatchedField } from './vehicles.types';
 import { canAddVehicle, getVehicleLimitConfig } from '../../../core/config/feature-tiers';
 import { UserProfileRepository } from '../../user-profile/data/user-profile.repository';
 import { SubscriptionTier } from '../../user-profile/domain/user-profile.types';
@@ -593,6 +594,72 @@ export class VehiclesService {
     await cacheService.del(cacheKey);
   }
 
+  /**
+   * Check vin_cache for existing VIN data.
+   * Format-aware: validates raw_data has `success` field (Gemini format).
+   * Old NHTSA-format entries are treated as cache misses and expire via TTL.
+   */
+  async getVinCached(vin: string): Promise<VinDecodeResponse | null> {
+    try {
+      const result = await this.pool.query<{
+        raw_data: any;
+        cached_at: Date;
+      }>(
+        `SELECT raw_data, cached_at
+         FROM vin_cache
+         WHERE vin = $1
+         AND cached_at > NOW() - INTERVAL '365 days'`,
+        [vin]
+      );
+
+      if (result.rows.length === 0) {
+        return null;
+      }
+
+      const rawData = result.rows[0].raw_data;
+
+      // Format-aware check: Gemini responses have `success` field,
+      // old NHTSA responses do not. Treat old format as cache miss.
+      if (!rawData || typeof rawData !== 'object' || !('success' in rawData)) {
+        logger.debug('VIN cache format mismatch (legacy NHTSA entry), treating as miss', { vin });
+        return null;
+      }
+
+      logger.debug('VIN cache hit', { vin });
+      return rawData as VinDecodeResponse;
+    } catch (error) {
+      logger.error('Failed to check VIN cache', { vin, error });
+      return null;
+    }
+  }
+
+  /**
+   * Save VIN decode response to cache with ON CONFLICT upsert.
+   */
+  async saveVinCache(vin: string, response: VinDecodeResponse): Promise<void> {
+    try {
+      await this.pool.query(
+        `INSERT INTO vin_cache (vin, make, model, year, engine_type, body_type, raw_data, cached_at)
+         VALUES ($1, $2, $3, $4, $5, $6, $7, NOW())
+         ON CONFLICT (vin) DO UPDATE SET
+           make = EXCLUDED.make,
+           model = EXCLUDED.model,
+           year = EXCLUDED.year,
+           engine_type = EXCLUDED.engine_type,
+           body_type = EXCLUDED.body_type,
+           raw_data = EXCLUDED.raw_data,
+           cached_at = NOW()
+         WHERE (vin_cache.raw_data->>'confidence')::float <= $8`,
+        [vin, response.make, response.model, response.year, response.engine, response.bodyType, JSON.stringify(response), response.confidence ?? 1]
+      );
+
+      logger.debug('VIN cached', { vin, confidence: response.confidence });
+    } catch (error) {
+      logger.error('Failed to cache VIN data', { vin, error });
+      // Don't throw - caching failure shouldn't break the decode flow
+    }
+  }
+  
   async getDropdownMakes(year: number): Promise<string[]> {
     const vehicleDataService = getVehicleDataService();
     const pool = getPool();
@@ -657,82 +724,88 @@ export class VehiclesService {
   }
 
   /**
-   * Map NHTSA decode response to internal decoded vehicle data format
+   * Map VIN decode response to internal decoded vehicle data format
    * with dropdown matching and confidence levels
    */
-  async mapNHTSAResponse(response: NHTSADecodeResponse): Promise<DecodedVehicleData> {
+  async mapVinDecodeResponse(response: VinDecodeResponse): Promise<DecodedVehicleData> {
     const vehicleDataService = getVehicleDataService();
     const pool = getPool();
 
-    // Extract raw values from NHTSA response
-    const nhtsaYear = NHTSAClient.extractYear(response);
-    const nhtsaMake = NHTSAClient.extractValue(response, 'Make');
-    const nhtsaModel = NHTSAClient.extractValue(response, 'Model');
-    const nhtsaTrim = NHTSAClient.extractValue(response, 'Trim');
-    const nhtsaBodyType = NHTSAClient.extractValue(response, 'Body Class');
-    const nhtsaDriveType = NHTSAClient.extractValue(response, 'Drive Type');
-    const nhtsaFuelType = NHTSAClient.extractValue(response, 'Fuel Type - Primary');
-    const nhtsaEngine = NHTSAClient.extractEngine(response);
-    const nhtsaTransmission = NHTSAClient.extractValue(response, 'Transmission Style');
+    // Read flat fields directly from Gemini response
+    const sourceYear = response.year;
+    const sourceMake = response.make;
+    const sourceModel = response.model;
+    const sourceTrim = response.trimLevel;
+    const sourceBodyType = response.bodyType;
+    const sourceDriveType = response.driveType;
+    const sourceFuelType = response.fuelType;
+    const sourceEngine = response.engine;
+    const sourceTransmission = response.transmission;
+
+    logger.debug('VIN decode raw values', {
+      vin: response.vin,
+      year: sourceYear, make: sourceMake, model: sourceModel,
+      trim: sourceTrim, confidence: response.confidence
+    });
 
     // Year is always high confidence if present (exact numeric match)
     const year: MatchedField<number> = {
-      value: nhtsaYear,
-      nhtsaValue: nhtsaYear?.toString() || null,
-      confidence: nhtsaYear ? 'high' : 'none'
+      value: sourceYear,
+      sourceValue: sourceYear?.toString() || null,
+      confidence: sourceYear ? 'high' : 'none'
     };
 
     // Match make against dropdown options
-    let make: MatchedField<string> = { value: null, nhtsaValue: nhtsaMake, confidence: 'none' };
-    if (nhtsaYear && nhtsaMake) {
-      const makes = await vehicleDataService.getMakes(pool, nhtsaYear);
-      make = this.matchField(nhtsaMake, makes);
+    let make: MatchedField<string> = { value: null, sourceValue: sourceMake, confidence: 'none' };
+    if (sourceYear && sourceMake) {
+      const makes = await vehicleDataService.getMakes(pool, sourceYear);
+      make = this.matchField(sourceMake, makes);
     }
 
     // Match model against dropdown options
-    let model: MatchedField<string> = { value: null, nhtsaValue: nhtsaModel, confidence: 'none' };
-    if (nhtsaYear && make.value && nhtsaModel) {
-      const models = await vehicleDataService.getModels(pool, nhtsaYear, make.value);
-      model = this.matchField(nhtsaModel, models);
+    let model: MatchedField<string> = { value: null, sourceValue: sourceModel, confidence: 'none' };
+    if (sourceYear && make.value && sourceModel) {
+      const models = await vehicleDataService.getModels(pool, sourceYear, make.value);
+      model = this.matchField(sourceModel, models);
     }
 
     // Match trim against dropdown options
-    let trimLevel: MatchedField<string> = { value: null, nhtsaValue: nhtsaTrim, confidence: 'none' };
-    if (nhtsaYear && make.value && model.value && nhtsaTrim) {
-      const trims = await vehicleDataService.getTrims(pool, nhtsaYear, make.value, model.value);
-      trimLevel = this.matchField(nhtsaTrim, trims);
+    let trimLevel: MatchedField<string> = { value: null, sourceValue: sourceTrim, confidence: 'none' };
+    if (sourceYear && make.value && model.value && sourceTrim) {
+      const trims = await vehicleDataService.getTrims(pool, sourceYear, make.value, model.value);
+      trimLevel = this.matchField(sourceTrim, trims);
     }
 
     // Match engine against dropdown options
-    let engine: MatchedField<string> = { value: null, nhtsaValue: nhtsaEngine, confidence: 'none' };
-    if (nhtsaYear && make.value && model.value && trimLevel.value && nhtsaEngine) {
-      const engines = await vehicleDataService.getEngines(pool, nhtsaYear, make.value, model.value, trimLevel.value);
-      engine = this.matchField(nhtsaEngine, engines);
+    let engine: MatchedField<string> = { value: null, sourceValue: sourceEngine, confidence: 'none' };
+    if (sourceYear && make.value && model.value && trimLevel.value && sourceEngine) {
+      const engines = await vehicleDataService.getEngines(pool, sourceYear, make.value, model.value, trimLevel.value);
+      engine = this.matchField(sourceEngine, engines);
     }
 
     // Match transmission against dropdown options
-    let transmission: MatchedField<string> = { value: null, nhtsaValue: nhtsaTransmission, confidence: 'none' };
-    if (nhtsaYear && make.value && model.value && trimLevel.value && nhtsaTransmission) {
-      const transmissions = await vehicleDataService.getTransmissionsForTrim(pool, nhtsaYear, make.value, model.value, trimLevel.value);
-      transmission = this.matchField(nhtsaTransmission, transmissions);
+    let transmission: MatchedField<string> = { value: null, sourceValue: sourceTransmission, confidence: 'none' };
+    if (sourceYear && make.value && model.value && trimLevel.value && sourceTransmission) {
+      const transmissions = await vehicleDataService.getTransmissionsForTrim(pool, sourceYear, make.value, model.value, trimLevel.value);
+      transmission = this.matchField(sourceTransmission, transmissions);
     }
 
     // Body type, drive type, and fuel type are display-only (no dropdown matching)
     const bodyType: MatchedField<string> = {
       value: null,
-      nhtsaValue: nhtsaBodyType,
+      sourceValue: sourceBodyType,
       confidence: 'none'
     };
 
     const driveType: MatchedField<string> = {
       value: null,
-      nhtsaValue: nhtsaDriveType,
+      sourceValue: sourceDriveType,
       confidence: 'none'
     };
 
     const fuelType: MatchedField<string> = {
       value: null,
-      nhtsaValue: nhtsaFuelType,
+      sourceValue: sourceFuelType,
       confidence: 'none'
     };
 
@@ -754,42 +827,62 @@ export class VehiclesService {
    * Returns the matched dropdown value with confidence level
    * Matching order: exact -> normalized -> prefix -> contains
    */
-  private matchField(nhtsaValue: string, options: string[]): MatchedField<string> {
-    if (!nhtsaValue || options.length === 0) {
-      return { value: null, nhtsaValue, confidence: 'none' };
+  private matchField(sourceValue: string, options: string[]): MatchedField<string> {
+    if (!sourceValue || options.length === 0) {
+      return { value: null, sourceValue, confidence: 'none' };
     }
 
-    const normalizedNhtsa = nhtsaValue.toLowerCase().trim();
+    const normalizedSource = sourceValue.toLowerCase().trim();
 
     // Try exact case-insensitive match
-    const exactMatch = options.find(opt => opt.toLowerCase().trim() === normalizedNhtsa);
+    const exactMatch = options.find(opt => opt.toLowerCase().trim() === normalizedSource);
     if (exactMatch) {
-      return { value: exactMatch, nhtsaValue, confidence: 'high' };
+      return { value: exactMatch, sourceValue, confidence: 'high' };
     }
 
     // Try normalized comparison (remove special chars)
     const normalizeForCompare = (s: string) => s.toLowerCase().replace(/[^a-z0-9]/g, '');
-    const normalizedNhtsaClean = normalizeForCompare(nhtsaValue);
+    const normalizedSourceClean = normalizeForCompare(sourceValue);
 
-    const normalizedMatch = options.find(opt => normalizeForCompare(opt) === normalizedNhtsaClean);
+    const normalizedMatch = options.find(opt => normalizeForCompare(opt) === normalizedSourceClean);
     if (normalizedMatch) {
-      return { value: normalizedMatch, nhtsaValue, confidence: 'medium' };
+      return { value: normalizedMatch, sourceValue, confidence: 'medium' };
     }
 
-    // Try prefix match - option starts with NHTSA value
-    const prefixMatch = options.find(opt => opt.toLowerCase().trim().startsWith(normalizedNhtsa));
+    // Try prefix match - option starts with source value
+    const prefixMatch = options.find(opt => opt.toLowerCase().trim().startsWith(normalizedSource));
     if (prefixMatch) {
-      return { value: prefixMatch, nhtsaValue, confidence: 'medium' };
+      return { value: prefixMatch, sourceValue, confidence: 'medium' };
     }
 
-    // Try contains match - option contains NHTSA value
-    const containsMatch = options.find(opt => opt.toLowerCase().trim().includes(normalizedNhtsa));
+    // Try contains match - option contains source value
+    const containsMatch = options.find(opt => opt.toLowerCase().trim().includes(normalizedSource));
     if (containsMatch) {
-      return { value: containsMatch, nhtsaValue, confidence: 'medium' };
+      return { value: containsMatch, sourceValue, confidence: 'medium' };
     }
 
-    // No match found - return NHTSA value as hint with no match
-    return { value: null, nhtsaValue, confidence: 'none' };
+    // Try reverse contains - source value contains option (e.g., source "X5 xDrive35i" contains option "X5")
+    // Prefer the longest matching option to avoid false positives (e.g., "X5 M" over "X5")
+    const reverseMatches = options.filter(opt => {
+      const normalizedOpt = opt.toLowerCase().trim();
+      return normalizedSource.includes(normalizedOpt) && normalizedOpt.length > 0;
+    });
+    if (reverseMatches.length > 0) {
+      const bestMatch = reverseMatches.reduce((a, b) => a.length >= b.length ? a : b);
+      return { value: bestMatch, sourceValue, confidence: 'medium' };
+    }
+
+    // Try word-start match - source starts with option + separator (e.g., "X5 xDrive" starts with "X5 ")
+    const wordStartMatch = options.find(opt => {
+      const normalizedOpt = opt.toLowerCase().trim();
+      return normalizedSource.startsWith(normalizedOpt + ' ') || normalizedSource.startsWith(normalizedOpt + '-');
+    });
+    if (wordStartMatch) {
+      return { value: wordStartMatch, sourceValue, confidence: 'medium' };
+    }
+
+    // No match found - return source value as hint with no match
+    return { value: null, sourceValue, confidence: 'none' };
   }
 
   private toResponse(vehicle: Vehicle): VehicleResponse {

backend/src/features/vehicles/domain/vehicles.types.ts

@@ -215,3 +215,53 @@ export interface TCOResponse {
   distanceUnit: string;
   currencyCode: string;
 }
+
+/** Confidence level for matched dropdown values */
+export type MatchConfidence = 'high' | 'medium' | 'none';
+
+/** Matched field with confidence indicator */
+export interface MatchedField<T> {
+  value: T | null;
+  sourceValue: string | null;
+  confidence: MatchConfidence;
+}
+
+/**
+ * Decoded vehicle data with match confidence per field.
+ * Maps VIN decode response fields to internal field names.
+ */
+export interface DecodedVehicleData {
+  year: MatchedField<number>;
+  make: MatchedField<string>;
+  model: MatchedField<string>;
+  trimLevel: MatchedField<string>;
+  bodyType: MatchedField<string>;
+  driveType: MatchedField<string>;
+  fuelType: MatchedField<string>;
+  engine: MatchedField<string>;
+  transmission: MatchedField<string>;
+}
+
+/** Cached VIN data from vin_cache table */
+export interface VinCacheEntry {
+  vin: string;
+  make: string | null;
+  model: string | null;
+  year: number | null;
+  engineType: string | null;
+  bodyType: string | null;
+  rawData: import('../../ocr/domain/ocr.types').VinDecodeResponse;
+  cachedAt: Date;
+}
+
+/** VIN decode request body */
+export interface DecodeVinRequest {
+  vin: string;
+}
+
+/** VIN decode error response */
+export interface VinDecodeError {
+  error: 'INVALID_VIN' | 'VIN_DECODE_FAILED' | 'TIER_REQUIRED';
+  message: string;
+  details?: string;
+}

backend/src/features/vehicles/external/CLAUDE.md

@@ -5,9 +5,3 @@
 | File | What | When to read |
 | ---- | ---- | ------------ |
 | `README.md` | Integration patterns, adding new services | Understanding external service conventions |
-
-## Subdirectories
-
-| Directory | What | When to read |
-| --------- | ---- | ------------ |
-| `nhtsa/` | NHTSA vPIC API client for VIN decoding | VIN decode feature work |

backend/src/features/vehicles/external/README.md

@@ -15,7 +15,7 @@ Each integration follows this structure:
 ## Adding New Integrations
 
 1. Create subdirectory: `external/{service}/`
-2. Add client: `{service}.client.ts` following NHTSAClient pattern
+2. Add client: `{service}.client.ts` following the axios-based client pattern
 3. Add types: `{service}.types.ts`
 4. Update `CLAUDE.md` with new directory
 5. Add tests in `tests/unit/{service}.client.test.ts`

backend/src/features/vehicles/external/nhtsa/index.ts

@@ -1,16 +0,0 @@
-/**
- * @ai-summary NHTSA vPIC integration exports
- * @ai-context Public API for VIN decoding functionality
- */
-
-export { NHTSAClient } from './nhtsa.client';
-export type {
-  NHTSADecodeResponse,
-  NHTSAResult,
-  DecodedVehicleData,
-  MatchedField,
-  MatchConfidence,
-  VinCacheEntry,
-  DecodeVinRequest,
-  VinDecodeError,
-} from './nhtsa.types';

backend/src/features/vehicles/external/nhtsa/nhtsa.client.ts

@@ -1,235 +0,0 @@
-/**
- * @ai-summary NHTSA vPIC API client for VIN decoding
- * @ai-context Fetches vehicle data from NHTSA and caches results
- */
-
-import axios, { AxiosError } from 'axios';
-import { logger } from '../../../../core/logging/logger';
-import { NHTSADecodeResponse, VinCacheEntry } from './nhtsa.types';
-import { Pool } from 'pg';
-
-/**
- * VIN validation regex
- * - 17 characters
- * - Excludes I, O, Q (not used in VINs)
- * - Alphanumeric only
- */
-const VIN_REGEX = /^[A-HJ-NPR-Z0-9]{17}$/;
-
-/**
- * Cache TTL: 1 year (VIN data is static - vehicle specs don't change)
- */
-const CACHE_TTL_SECONDS = 365 * 24 * 60 * 60;
-
-export class NHTSAClient {
-  private readonly baseURL = 'https://vpic.nhtsa.dot.gov/api';
-  private readonly timeout = 5000; // 5 seconds
-
-  constructor(private readonly pool: Pool) {}
-
-  /**
-   * Validate VIN format
-   * @throws Error if VIN format is invalid
-   */
-  validateVin(vin: string): string {
-    const sanitized = vin.trim().toUpperCase();
-
-    if (!sanitized) {
-      throw new Error('VIN is required');
-    }
-
-    if (!VIN_REGEX.test(sanitized)) {
-      throw new Error('Invalid VIN format. VIN must be exactly 17 characters and contain only letters (except I, O, Q) and numbers.');
-    }
-
-    return sanitized;
-  }
-
-  /**
-   * Check cache for existing VIN data
-   */
-  async getCached(vin: string): Promise<VinCacheEntry | null> {
-    try {
-      const result = await this.pool.query<{
-        vin: string;
-        make: string | null;
-        model: string | null;
-        year: number | null;
-        engine_type: string | null;
-        body_type: string | null;
-        raw_data: NHTSADecodeResponse;
-        cached_at: Date;
-      }>(
-        `SELECT vin, make, model, year, engine_type, body_type, raw_data, cached_at
-         FROM vin_cache
-         WHERE vin = $1
-         AND cached_at > NOW() - INTERVAL '${CACHE_TTL_SECONDS} seconds'`,
-        [vin]
-      );
-
-      if (result.rows.length === 0) {
-        return null;
-      }
-
-      const row = result.rows[0];
-      return {
-        vin: row.vin,
-        make: row.make,
-        model: row.model,
-        year: row.year,
-        engineType: row.engine_type,
-        bodyType: row.body_type,
-        rawData: row.raw_data,
-        cachedAt: row.cached_at,
-      };
-    } catch (error) {
-      logger.error('Failed to check VIN cache', { vin, error });
-      return null;
-    }
-  }
-
-  /**
-   * Save VIN data to cache
-   */
-  async saveToCache(vin: string, response: NHTSADecodeResponse): Promise<void> {
-    try {
-      const findValue = (variable: string): string | null => {
-        const result = response.Results.find(r => r.Variable === variable);
-        return result?.Value || null;
-      };
-
-      const year = findValue('Model Year');
-      const make = findValue('Make');
-      const model = findValue('Model');
-      const engineType = findValue('Engine Model');
-      const bodyType = findValue('Body Class');
-
-      await this.pool.query(
-        `INSERT INTO vin_cache (vin, make, model, year, engine_type, body_type, raw_data, cached_at)
-         VALUES ($1, $2, $3, $4, $5, $6, $7, NOW())
-         ON CONFLICT (vin) DO UPDATE SET
-           make = EXCLUDED.make,
-           model = EXCLUDED.model,
-           year = EXCLUDED.year,
-           engine_type = EXCLUDED.engine_type,
-           body_type = EXCLUDED.body_type,
-           raw_data = EXCLUDED.raw_data,
-           cached_at = NOW()`,
-        [vin, make, model, year ? parseInt(year) : null, engineType, bodyType, JSON.stringify(response)]
-      );
-
-      logger.debug('VIN cached', { vin });
-    } catch (error) {
-      logger.error('Failed to cache VIN data', { vin, error });
-      // Don't throw - caching failure shouldn't break the decode flow
-    }
-  }
-
-  /**
-   * Decode VIN using NHTSA vPIC API
-   * @param vin - 17-character VIN
-   * @returns Raw NHTSA decode response
-   * @throws Error if VIN is invalid or API call fails
-   */
-  async decodeVin(vin: string): Promise<NHTSADecodeResponse> {
-    // Validate and sanitize VIN
-    const sanitizedVin = this.validateVin(vin);
-
-    // Check cache first
-    const cached = await this.getCached(sanitizedVin);
-    if (cached) {
-      logger.debug('VIN cache hit', { vin: sanitizedVin });
-      return cached.rawData;
-    }
-
-    // Call NHTSA API
-    logger.info('Calling NHTSA vPIC API', { vin: sanitizedVin });
-
-    try {
-      const response = await axios.get<NHTSADecodeResponse>(
-        `${this.baseURL}/vehicles/decodevin/${sanitizedVin}`,
-        {
-          params: { format: 'json' },
-          timeout: this.timeout,
-        }
-      );
-
-      // Check for NHTSA-level errors
-      if (response.data.Count === 0) {
-        throw new Error('NHTSA returned no results for this VIN');
-      }
-
-      // Check for error messages in results
-      const errorResult = response.data.Results.find(
-        r => r.Variable === 'Error Code' && r.Value && r.Value !== '0'
-      );
-      if (errorResult) {
-        const errorText = response.data.Results.find(r => r.Variable === 'Error Text');
-        throw new Error(`NHTSA error: ${errorText?.Value || 'Unknown error'}`);
-      }
-
-      // Cache the successful response
-      await this.saveToCache(sanitizedVin, response.data);
-
-      return response.data;
-    } catch (error) {
-      if (axios.isAxiosError(error)) {
-        const axiosError = error as AxiosError;
-        if (axiosError.code === 'ECONNABORTED') {
-          logger.error('NHTSA API timeout', { vin: sanitizedVin });
-          throw new Error('NHTSA API request timed out. Please try again.');
-        }
-        if (axiosError.response) {
-          logger.error('NHTSA API error response', {
-            vin: sanitizedVin,
-            status: axiosError.response.status,
-            data: axiosError.response.data,
-          });
-          throw new Error(`NHTSA API error: ${axiosError.response.status}`);
-        }
-        logger.error('NHTSA API network error', { vin: sanitizedVin, message: axiosError.message });
-        throw new Error('Unable to connect to NHTSA API. Please try again later.');
-      }
-      throw error;
-    }
-  }
-
-  /**
-   * Extract a specific value from NHTSA response
-   */
-  static extractValue(response: NHTSADecodeResponse, variable: string): string | null {
-    const result = response.Results.find(r => r.Variable === variable);
-    return result?.Value?.trim() || null;
-  }
-
-  /**
-   * Extract year from NHTSA response
-   */
-  static extractYear(response: NHTSADecodeResponse): number | null {
-    const value = NHTSAClient.extractValue(response, 'Model Year');
-    if (!value) return null;
-    const parsed = parseInt(value, 10);
-    return isNaN(parsed) ? null : parsed;
-  }
-
-  /**
-   * Extract engine description from NHTSA response
-   * Combines multiple engine-related fields
-   */
-  static extractEngine(response: NHTSADecodeResponse): string | null {
-    const engineModel = NHTSAClient.extractValue(response, 'Engine Model');
-    if (engineModel) return engineModel;
-
-    // Build engine description from components
-    const cylinders = NHTSAClient.extractValue(response, 'Engine Number of Cylinders');
-    const displacement = NHTSAClient.extractValue(response, 'Displacement (L)');
-    const fuelType = NHTSAClient.extractValue(response, 'Fuel Type - Primary');
-
-    const parts: string[] = [];
-    if (cylinders) parts.push(`${cylinders}-Cylinder`);
-    if (displacement) parts.push(`${displacement}L`);
-    if (fuelType && fuelType !== 'Gasoline') parts.push(fuelType);
-
-    return parts.length > 0 ? parts.join(' ') : null;
-  }
-}

backend/src/features/vehicles/external/nhtsa/nhtsa.types.ts

@@ -1,96 +0,0 @@
-/**
- * @ai-summary Type definitions for NHTSA vPIC API
- * @ai-context Defines request/response types for VIN decoding
- */
-
-/**
- * Individual result from NHTSA DecodeVin API
- */
-export interface NHTSAResult {
-  Value: string | null;
-  ValueId: string | null;
-  Variable: string;
-  VariableId: number;
-}
-
-/**
- * Raw response from NHTSA DecodeVin API
- * GET https://vpic.nhtsa.dot.gov/api/vehicles/decodevin/{VIN}?format=json
- */
-export interface NHTSADecodeResponse {
-  Count: number;
-  Message: string;
-  SearchCriteria: string;
-  Results: NHTSAResult[];
-}
-
-/**
- * Confidence level for matched dropdown values
- */
-export type MatchConfidence = 'high' | 'medium' | 'none';
-
-/**
- * Matched field with confidence indicator
- */
-export interface MatchedField<T> {
-  value: T | null;
-  nhtsaValue: string | null;
-  confidence: MatchConfidence;
-}
-
-/**
- * Decoded vehicle data with match confidence per field
- * Maps NHTSA response fields to internal field names (camelCase)
- *
- * NHTSA Field Mappings:
- * - ModelYear -> year
- * - Make -> make
- * - Model -> model
- * - Trim -> trimLevel
- * - BodyClass -> bodyType
- * - DriveType -> driveType
- * - FuelTypePrimary -> fuelType
- * - EngineModel / EngineCylinders + EngineDisplacementL -> engine
- * - TransmissionStyle -> transmission
- */
-export interface DecodedVehicleData {
-  year: MatchedField<number>;
-  make: MatchedField<string>;
-  model: MatchedField<string>;
-  trimLevel: MatchedField<string>;
-  bodyType: MatchedField<string>;
-  driveType: MatchedField<string>;
-  fuelType: MatchedField<string>;
-  engine: MatchedField<string>;
-  transmission: MatchedField<string>;
-}
-
-/**
- * Cached VIN data from vin_cache table
- */
-export interface VinCacheEntry {
-  vin: string;
-  make: string | null;
-  model: string | null;
-  year: number | null;
-  engineType: string | null;
-  bodyType: string | null;
-  rawData: NHTSADecodeResponse;
-  cachedAt: Date;
-}
-
-/**
- * VIN decode request body
- */
-export interface DecodeVinRequest {
-  vin: string;
-}
-
-/**
- * VIN decode error response
- */
-export interface VinDecodeError {
-  error: 'INVALID_VIN' | 'VIN_DECODE_FAILED' | 'TIER_REQUIRED';
-  message: string;
-  details?: string;
-}

config/app/ci.yml

@@ -22,11 +22,6 @@ platform:
       url: http://mvp-platform-vehicles-api:8000
       timeout: 5s
 
-external:
-  vpic:
-    url: https://vpic.nhtsa.dot.gov/api/vehicles
-    timeout: 10s
-
 service:
   name: mvp-backend
 

config/app/production.yml.example

@@ -21,5 +21,3 @@ auth0:
   domain: motovaultpro.us.auth0.com
   audience: https://api.motovaultpro.com
 
-external:
-  vpic_api_url: https://vpic.nhtsa.dot.gov/api/vehicles

config/shared/production.yml

@@ -107,9 +107,6 @@ external_services:
   google_maps:
     base_url: https://maps.googleapis.com/maps/api
 
-  vpic:
-    base_url: https://vpic.nhtsa.dot.gov/api/vehicles
-
 # Development Configuration
 development:
   debug_enabled: false

docker-compose.yml

@@ -206,8 +206,8 @@ services:
       VISION_MONTHLY_LIMIT: "1000"
       # Vertex AI / Gemini configuration (maintenance schedule extraction)
       VERTEX_AI_PROJECT: motovaultpro
-      VERTEX_AI_LOCATION: us-central1
-      GEMINI_MODEL: gemini-2.5-flash
+      VERTEX_AI_LOCATION: global
+      GEMINI_MODEL: gemini-3-flash-preview
     volumes:
       - /tmp/vin-debug:/tmp/vin-debug
       - ./secrets/app/auth0-ocr-client-id.txt:/run/secrets/auth0-ocr-client-id:ro

docs/PLATFORM-SERVICES.md

@@ -35,7 +35,7 @@ The platform provides vehicle hierarchical data lookups:
 VIN decoding is planned but not yet implemented. Future capabilities will include:
 - `GET /api/platform/vehicle?vin={vin}` - Decode VIN to vehicle details
 - PostgreSQL-based VIN decode function
-- NHTSA vPIC API fallback with circuit breaker
+- Gemini VIN decode via OCR service
 - Redis caching (7-day TTL for successful decodes)
 
 **Data Source**: Vehicle data from standardized sources

docs/TESTING.md

@@ -74,7 +74,7 @@ docker compose exec mvp-frontend npm test -- --coverage
 
 Example: `vehicles.service.test.ts`
 - Tests VIN validation logic
-- Tests vehicle creation with mocked vPIC responses
+- Tests vehicle creation with mocked OCR service responses
 - Tests caching behavior with mocked Redis
 - Tests error handling paths
 
@@ -194,7 +194,7 @@ All 15 features have test suites with unit and/or integration tests:
 - `vehicles` - Unit + integration tests
 
 ### Mock Strategy
-- **External APIs**: Completely mocked (vPIC, Google Maps)
+- **External APIs**: Completely mocked (OCR service, Google Maps)
 - **Database**: Real database with transactions
 - **Redis**: Mocked for unit tests, real for integration
 - **Auth**: Mocked JWT tokens for protected endpoints
@@ -319,8 +319,8 @@ describe('Error Handling', () => {
     ).rejects.toThrow('Invalid VIN format');
   });
   
-  it('should handle vPIC API failure', async () => {
-    mockVpicClient.decode.mockRejectedValue(new Error('API down'));
+  it('should handle OCR service failure', async () => {
+    mockOcrClient.decodeVin.mockRejectedValue(new Error('API down'));
 
     const result = await vehicleService.create(validVehicle, 'user123');
     expect(result.make).toBeNull(); // Graceful degradation

docs/USER-GUIDE.md

@@ -644,7 +644,7 @@ When you attempt to use a Pro feature on the Free tier, an **Upgrade Required**
 
 ### VIN Camera Scanning and Decode (Pro)
 
-**What it does:** Use your device camera to photograph your vehicle's VIN plate, and the system automatically reads the VIN using OCR (Optical Character Recognition) and decodes it from the NHTSA database.
+**What it does:** Use your device camera to photograph your vehicle's VIN plate, and the system automatically reads the VIN using OCR (Optical Character Recognition) and decodes it from the vehicle database.
 
 **How to use it:**
 
@@ -655,7 +655,7 @@ When you attempt to use a Pro feature on the Free tier, an **Upgrade Required**
 5. A **VIN OCR Review modal** appears showing the detected VIN with confidence indicators
 6. Confirm or correct the VIN, then click **Accept**
 7. Click the **Decode VIN** button
-8. The system queries the NHTSA database and auto-populates: Year, Make, Model, Engine, Transmission, and Trim
+8. The system queries the vehicle database and auto-populates: Year, Make, Model, Engine, Transmission, and Trim
 9. Review the pre-filled fields and complete the remaining details
 
 This eliminates manual data entry errors and ensures accurate vehicle specifications.

frontend/src/features/vehicles/api/vehicles.api.ts

@@ -82,7 +82,7 @@ export const vehiclesApi = {
   },
 
   /**
-   * Decode VIN using NHTSA vPIC API
+   * Decode VIN using VIN decode service
    * Requires Pro or Enterprise tier
    */
   decodeVin: async (vin: string): Promise<DecodedVehicleData> => {

frontend/src/features/vehicles/components/VehicleForm.tsx

@@ -114,6 +114,7 @@ export const VehicleForm: React.FC<VehicleFormProps> = ({
   const [isDecoding, setIsDecoding] = useState(false);
   const [showUpgradeDialog, setShowUpgradeDialog] = useState(false);
   const [decodeError, setDecodeError] = useState<string | null>(null);
+  const [decodeHint, setDecodeHint] = useState<string | null>(null);
 
   // VIN OCR capture hook
   const vinOcr = useVinOcr();
@@ -507,7 +508,7 @@ export const VehicleForm: React.FC<VehicleFormProps> = ({
 
   /**
    * Handle VIN decode button click
-   * Calls NHTSA API and populates empty form fields
+   * Calls VIN decode service and populates empty form fields
    */
   const handleDecodeVin = async () => {
     // Check tier access first
@@ -524,6 +525,7 @@ export const VehicleForm: React.FC<VehicleFormProps> = ({
 
     setIsDecoding(true);
     setDecodeError(null);
+    setDecodeHint(null);
 
     try {
       const decoded = await vehiclesApi.decodeVin(vin);
@@ -588,6 +590,21 @@ export const VehicleForm: React.FC<VehicleFormProps> = ({
         setValue('transmission', decoded.transmission.value);
       }
 
+      // Check if decode returned data but matching failed for key fields
+      const hasMatchedValue = decoded.year.value || decoded.make.value || decoded.model.value;
+      const hasSourceValue = decoded.year.sourceValue || decoded.make.sourceValue || decoded.model.sourceValue;
+      if (!hasMatchedValue && hasSourceValue) {
+        const parts = [
+          decoded.year.sourceValue,
+          decoded.make.sourceValue,
+          decoded.model.sourceValue,
+          decoded.trimLevel.sourceValue
+        ].filter(Boolean);
+        setDecodeHint(
+          `Could not match VIN data to dropdowns. Decoded as: ${parts.join(' ')}. Please select values manually.`
+        );
+      }
+
       setLoadingDropdowns(false);
       isVinDecoding.current = false;
     } catch (error: any) {
@@ -671,6 +688,9 @@ export const VehicleForm: React.FC<VehicleFormProps> = ({
         {decodeError && (
           <p className="mt-1 text-sm text-red-600 dark:text-red-400">{decodeError}</p>
         )}
+        {decodeHint && (
+          <p className="mt-1 text-sm text-amber-600 dark:text-amber-400">{decodeHint}</p>
+        )}
         {vinOcr.error && (
           <p className="mt-1 text-sm text-red-600 dark:text-red-400">{vinOcr.error}</p>
         )}

frontend/src/features/vehicles/components/VinOcrReviewModal.tsx

@@ -95,8 +95,8 @@ const ReviewContent: React.FC<{
   const [selectedEngine, setSelectedEngine] = useState('');
   const [selectedTransmission, setSelectedTransmission] = useState('');
 
-  // NHTSA reference values for unmatched fields
-  const [nhtsaRefs, setNhtsaRefs] = useState<Record<string, string | null>>({});
+  // Source reference values for unmatched fields
+  const [sourceRefs, setSourceRefs] = useState<Record<string, string | null>>({});
 
   // Initialize dropdown options and pre-select decoded values
   useEffect(() => {
@@ -109,13 +109,13 @@ const ReviewContent: React.FC<{
 
         if (!decodedVehicle) return;
 
-        // Store NHTSA reference values for unmatched fields
-        setNhtsaRefs({
-          make: decodedVehicle.make.confidence === 'none' ? decodedVehicle.make.nhtsaValue : null,
-          model: decodedVehicle.model.confidence === 'none' ? decodedVehicle.model.nhtsaValue : null,
-          trim: decodedVehicle.trimLevel.confidence === 'none' ? decodedVehicle.trimLevel.nhtsaValue : null,
-          engine: decodedVehicle.engine.confidence === 'none' ? decodedVehicle.engine.nhtsaValue : null,
-          transmission: decodedVehicle.transmission.confidence === 'none' ? decodedVehicle.transmission.nhtsaValue : null,
+        // Store source reference values for unmatched fields
+        setSourceRefs({
+          make: decodedVehicle.make.confidence === 'none' ? decodedVehicle.make.sourceValue : null,
+          model: decodedVehicle.model.confidence === 'none' ? decodedVehicle.model.sourceValue : null,
+          trim: decodedVehicle.trimLevel.confidence === 'none' ? decodedVehicle.trimLevel.sourceValue : null,
+          engine: decodedVehicle.engine.confidence === 'none' ? decodedVehicle.engine.sourceValue : null,
+          transmission: decodedVehicle.transmission.confidence === 'none' ? decodedVehicle.transmission.sourceValue : null,
         });
 
         const yearValue = decodedVehicle.year.value;
@@ -277,9 +277,9 @@ const ReviewContent: React.FC<{
     });
   };
 
-  /** Show NHTSA reference when field had no dropdown match */
-  const nhtsaHint = (field: string) => {
-    const ref = nhtsaRefs[field];
+  /** Show source reference when field had no dropdown match */
+  const sourceHint = (field: string) => {
+    const ref = sourceRefs[field];
     if (!ref) return null;
     // Only show hint when no value is currently selected
     const selected: Record<string, string> = {
@@ -292,7 +292,7 @@ const ReviewContent: React.FC<{
     if (selected[field]) return null;
     return (
       <p className="mt-1 text-xs text-gray-500 dark:text-titanio">
-        NHTSA returned: {ref}
+        Decoded value: {ref}
       </p>
     );
   };
@@ -409,7 +409,7 @@ const ReviewContent: React.FC<{
                 </option>
               ))}
             </select>
-            {nhtsaHint('make')}
+            {sourceHint('make')}
           </div>
 
           {/* Model */}
@@ -439,7 +439,7 @@ const ReviewContent: React.FC<{
                 </option>
               ))}
             </select>
-            {nhtsaHint('model')}
+            {sourceHint('model')}
           </div>
 
           {/* Trim */}
@@ -469,7 +469,7 @@ const ReviewContent: React.FC<{
                 </option>
               ))}
             </select>
-            {nhtsaHint('trim')}
+            {sourceHint('trim')}
           </div>
 
           {/* Engine */}
@@ -499,7 +499,7 @@ const ReviewContent: React.FC<{
                 </option>
               ))}
             </select>
-            {nhtsaHint('engine')}
+            {sourceHint('engine')}
           </div>
 
           {/* Transmission */}
@@ -529,7 +529,7 @@ const ReviewContent: React.FC<{
                 </option>
               ))}
             </select>
-            {nhtsaHint('transmission')}
+            {sourceHint('transmission')}
           </div>
         </div>
       </Box>

frontend/src/features/vehicles/hooks/useVinOcr.ts

@@ -1,5 +1,5 @@
 /**
- * @ai-summary Hook to orchestrate VIN OCR extraction and NHTSA decode
+ * @ai-summary Hook to orchestrate VIN OCR extraction and VIN decode
  * @ai-context Handles camera capture -> OCR extraction -> VIN decode flow
  */
 
@@ -109,7 +109,7 @@ export function useVinOcr(): UseVinOcrReturn {
         );
       }
 
-      // Step 2: Decode VIN using NHTSA
+      // Step 2: Decode VIN
       setProcessingStep('decoding');
       let decodedVehicle: DecodedVehicleData | null = null;
       let decodeError: string | null = null;
@@ -121,7 +121,7 @@ export function useVinOcr(): UseVinOcrReturn {
         if (err.response?.data?.error === 'TIER_REQUIRED') {
           decodeError = 'VIN decode requires Pro or Enterprise subscription';
         } else if (err.response?.data?.error === 'INVALID_VIN') {
-          decodeError = 'VIN format is not recognized by NHTSA';
+          decodeError = 'VIN format is not recognized';
         } else {
           decodeError = 'Unable to decode vehicle information';
         }

frontend/src/features/vehicles/types/vehicles.types.ts

@@ -72,12 +72,12 @@ export type MatchConfidence = 'high' | 'medium' | 'none';
  */
 export interface MatchedField<T> {
   value: T | null;
-  nhtsaValue: string | null;
+  sourceValue: string | null;
   confidence: MatchConfidence;
 }
 
 /**
- * Decoded vehicle data from NHTSA vPIC API
+ * Decoded vehicle data from VIN decode
  * with match confidence per field
  */
 export interface DecodedVehicleData {

frontend/src/pages/GuidePage/sections/SubscriptionSection.tsx

@@ -43,7 +43,7 @@ export const SubscriptionSection = () => {
       </h3>
 
       <p className="text-titanio/70 leading-relaxed mb-4">
-        <strong className="text-avus">What it does:</strong> Use your device camera to photograph your vehicle's VIN plate, and the system automatically reads the VIN using OCR (Optical Character Recognition) and decodes it from the NHTSA database.
+        <strong className="text-avus">What it does:</strong> Use your device camera to photograph your vehicle's VIN plate, and the system automatically reads the VIN using OCR (Optical Character Recognition) and decodes it from the vehicle database.
       </p>
 
       <p className="text-titanio/70 leading-relaxed mb-4">
@@ -58,7 +58,7 @@ export const SubscriptionSection = () => {
         <li>A <strong className="text-avus">VIN OCR Review modal</strong> appears showing the detected VIN with confidence indicators</li>
         <li>Confirm or correct the VIN, then click <strong className="text-avus">Accept</strong></li>
         <li>Click the <strong className="text-avus">Decode VIN</strong> button</li>
-        <li>The system queries the NHTSA database and auto-populates: Year, Make, Model, Engine, Transmission, and Trim</li>
+        <li>The system queries the vehicle database and auto-populates: Year, Make, Model, Engine, Transmission, and Trim</li>
         <li>Review the pre-filled fields and complete the remaining details</li>
       </ol>
 

frontend/src/pages/GuidePage/sections/VehiclesSection.tsx

@@ -141,7 +141,7 @@ export const VehiclesSection = () => {
         <GuideScreenshot
           src="/guide/vin-decode-desktop.png"
           alt="VIN Decode feature showing auto-populated vehicle specifications"
-          caption="The VIN Decode feature automatically fills in vehicle details from the NHTSA database"
+          caption="The VIN Decode feature automatically fills in vehicle details from the vehicle database"
         />
       </div>
 

ocr/CLAUDE.md

@@ -1,6 +1,6 @@
 # ocr/
 
-Python OCR microservice. Primary engine: PaddleOCR PP-OCRv4 with optional Google Vision cloud fallback. Gemini 2.5 Flash for maintenance manual PDF extraction. Pluggable engine abstraction in `app/engines/`.
+Python OCR microservice. Primary engine: PaddleOCR PP-OCRv4 with optional Google Vision cloud fallback. Gemini 2.5 Flash for maintenance manual PDF extraction and VIN decode. Pluggable engine abstraction in `app/engines/`.
 
 ## Files
 

ocr/app/CLAUDE.md

@@ -19,7 +19,7 @@ Python OCR microservice (FastAPI). Primary engine: PaddleOCR PP-OCRv4 with optio
 | `models/` | Data models and schemas | Request/response types |
 | `patterns/` | Regex patterns and service name mapping (27 maintenance subtypes) | Pattern matching rules, service categorization |
 | `preprocessors/` | Image preprocessing pipeline | Image preparation before OCR |
-| `routers/` | FastAPI route handlers (/extract, /extract/receipt, /extract/manual, /jobs) | API endpoint changes |
+| `routers/` | FastAPI route handlers (/extract, /extract/receipt, /extract/manual, /decode, /jobs) | API endpoint changes |
 | `services/` | Business logic services (job queue with Redis) | Core OCR processing, async job management |
 | `table_extraction/` | Table detection and parsing | Structured data extraction from images |
 | `validators/` | Input validation | Validation rules |

ocr/app/config.py

@@ -32,7 +32,7 @@ class Settings:
         # Vertex AI / Gemini configuration
         self.vertex_ai_project: str = os.getenv("VERTEX_AI_PROJECT", "")
         self.vertex_ai_location: str = os.getenv(
-            "VERTEX_AI_LOCATION", "us-central1"
+            "VERTEX_AI_LOCATION", "global"
         )
         self.gemini_model: str = os.getenv("GEMINI_MODEL", "gemini-2.5-flash")
 

ocr/app/engines/CLAUDE.md

@@ -3,7 +3,7 @@
 OCR engine abstraction layer. Two categories of engines:
 
 1. **OcrEngine subclasses** (image-to-text): PaddleOCR, Google Vision, Hybrid. Accept image bytes, return text + confidence + word boxes.
-2. **GeminiEngine** (PDF-to-structured-data): Standalone module for maintenance schedule extraction via Vertex AI. Accepts PDF bytes, returns structured JSON. Not an OcrEngine subclass because the interface signatures differ.
+2. **GeminiEngine** (PDF-to-structured-data and VIN decode): Standalone module for maintenance schedule extraction and VIN decoding via Vertex AI. Accepts PDF bytes or VIN strings, returns structured JSON. Not an OcrEngine subclass because the interface signatures differ.
 
 ## Files
 
@@ -15,7 +15,7 @@ OCR engine abstraction layer. Two categories of engines:
 | `cloud_engine.py` | Google Vision TEXT_DETECTION fallback engine (WIF authentication) | Cloud OCR configuration, API quota |
 | `hybrid_engine.py` | Combines primary + fallback engine with confidence threshold switching | Engine selection logic, fallback behavior |
 | `engine_factory.py` | Factory function and engine registry for instantiation | Adding new engine types |
-| `gemini_engine.py` | Gemini 2.5 Flash integration for maintenance schedule extraction (Vertex AI SDK, 20MB PDF limit, structured JSON output) | Manual extraction debugging, Gemini configuration |
+| `gemini_engine.py` | Gemini 2.5 Flash integration for maintenance schedule extraction and VIN decoding (Vertex AI SDK, 20MB PDF limit, structured JSON output) | Manual extraction debugging, VIN decode, Gemini configuration |
 
 ## Engine Selection
 
@@ -30,4 +30,4 @@ create_engine(config)
 HybridEngine (tries primary, falls back if confidence < threshold)
 ```
 
-GeminiEngine is created independently by ManualExtractor, not through the engine factory.
+GeminiEngine is created independently by ManualExtractor and the VIN decode router, not through the engine factory.

ocr/app/engines/gemini_engine.py

@@ -1,4 +1,4 @@
-"""Gemini 2.5 Flash engine for maintenance schedule extraction from PDFs.
+"""Gemini 2.5 Flash engine for document understanding and VIN decode.
 
 Standalone module (does NOT extend OcrEngine) because Gemini performs
 semantic document understanding, not traditional OCR word-box extraction.
@@ -37,6 +37,31 @@ Do not include one-time procedures, troubleshooting steps, or warranty informati
 Return the results as a JSON object with a single "maintenanceSchedule" array.\
 """
 
+_VIN_DECODE_PROMPT = """\
+Given the VIN (Vehicle Identification Number) below, decode it and return the vehicle specifications.
+
+VIN: {vin}
+
+Return the vehicle's year, make, model, trim level, body type, drive type, fuel type, engine description, and transmission type. If a field cannot be determined from the VIN, return null for that field. Return a confidence score (0.0-1.0) indicating overall decode reliability.\
+"""
+
+_VIN_DECODE_SCHEMA: dict[str, Any] = {
+    "type": "object",
+    "properties": {
+        "year": {"type": "integer", "nullable": True},
+        "make": {"type": "string", "nullable": True},
+        "model": {"type": "string", "nullable": True},
+        "trimLevel": {"type": "string", "nullable": True},
+        "bodyType": {"type": "string", "nullable": True},
+        "driveType": {"type": "string", "nullable": True},
+        "fuelType": {"type": "string", "nullable": True},
+        "engine": {"type": "string", "nullable": True},
+        "transmission": {"type": "string", "nullable": True},
+        "confidence": {"type": "number"},
+    },
+    "required": ["confidence"],
+}
+
 _RESPONSE_SCHEMA: dict[str, Any] = {
     "type": "object",
     "properties": {
@@ -70,6 +95,22 @@ class GeminiProcessingError(GeminiEngineError):
     """Raised when Gemini fails to process a document."""
 
 
+@dataclass
+class VinDecodeResult:
+    """Result from Gemini VIN decode."""
+
+    year: int | None = None
+    make: str | None = None
+    model: str | None = None
+    trim_level: str | None = None
+    body_type: str | None = None
+    drive_type: str | None = None
+    fuel_type: str | None = None
+    engine: str | None = None
+    transmission: str | None = None
+    confidence: float = 0.0
+
+
 @dataclass
 class MaintenanceItem:
     """A single extracted maintenance schedule item."""
@@ -89,13 +130,13 @@ class MaintenanceExtractionResult:
 
 
 class GeminiEngine:
-    """Gemini 2.5 Flash wrapper for maintenance schedule extraction.
+    """Gemini 2.5 Flash wrapper for maintenance schedule extraction and VIN decode.
 
     Standalone class (not an OcrEngine subclass) because Gemini performs
     semantic document understanding rather than traditional OCR.
 
     Uses lazy initialization: the Vertex AI client is not created until
-    the first ``extract_maintenance()`` call.
+    the first call to ``extract_maintenance()`` or ``decode_vin()``.
     """
 
     def __init__(self) -> None:
@@ -228,3 +269,60 @@ class GeminiEngine:
             raise GeminiProcessingError(
                 f"Gemini maintenance extraction failed: {exc}"
             ) from exc
+
+    def decode_vin(self, vin: str) -> VinDecodeResult:
+        """Decode a VIN string into structured vehicle data via Gemini.
+
+        Args:
+            vin: A 17-character Vehicle Identification Number.
+
+        Returns:
+            Structured vehicle specification result.
+
+        Raises:
+            GeminiProcessingError: If Gemini fails to decode the VIN.
+            GeminiUnavailableError: If the engine cannot be initialized.
+        """
+        model = self._get_model()
+
+        try:
+            from vertexai.generative_models import GenerationConfig  # type: ignore[import-untyped]
+
+            vin_config = GenerationConfig(
+                response_mime_type="application/json",
+                response_schema=_VIN_DECODE_SCHEMA,
+            )
+
+            prompt = _VIN_DECODE_PROMPT.format(vin=vin)
+            response = model.generate_content(
+                [prompt],
+                generation_config=vin_config,
+            )
+
+            raw = json.loads(response.text)
+
+            logger.info("Gemini decoded VIN %s (confidence=%.2f)", vin, raw.get("confidence", 0))
+
+            return VinDecodeResult(
+                year=raw.get("year"),
+                make=raw.get("make"),
+                model=raw.get("model"),
+                trim_level=raw.get("trimLevel"),
+                body_type=raw.get("bodyType"),
+                drive_type=raw.get("driveType"),
+                fuel_type=raw.get("fuelType"),
+                engine=raw.get("engine"),
+                transmission=raw.get("transmission"),
+                confidence=raw.get("confidence", 0.0),
+            )
+
+        except (GeminiEngineError,):
+            raise
+        except json.JSONDecodeError as exc:
+            raise GeminiProcessingError(
+                f"Gemini returned invalid JSON for VIN decode: {exc}"
+            ) from exc
+        except Exception as exc:
+            raise GeminiProcessingError(
+                f"Gemini VIN decode failed: {exc}"
+            ) from exc

ocr/app/main.py

@@ -6,7 +6,7 @@ from typing import AsyncIterator
 from fastapi import FastAPI
 
 from app.config import settings
-from app.routers import extract_router, jobs_router
+from app.routers import decode_router, extract_router, jobs_router
 from app.services import job_queue
 
 # Configure logging
@@ -36,6 +36,7 @@ app = FastAPI(
 )
 
 # Include routers
+app.include_router(decode_router)
 app.include_router(extract_router)
 app.include_router(jobs_router)
 
@@ -54,6 +55,7 @@ async def root() -> dict:
         "version": "1.0.0",
         "log_level": settings.log_level,
         "endpoints": [
+            "POST /decode/vin - VIN string decode via Gemini",
             "POST /extract - Synchronous OCR extraction",
             "POST /extract/vin - VIN-specific extraction with validation",
             "POST /extract/receipt - Receipt extraction (fuel, general)",

ocr/app/models/__init__.py

@@ -14,6 +14,8 @@ from .schemas import (
     ReceiptExtractedField,
     ReceiptExtractionResponse,
     VinAlternative,
+    VinDecodeRequest,
+    VinDecodeResponse,
     VinExtractionResponse,
 )
 
@@ -32,5 +34,7 @@ __all__ = [
     "ReceiptExtractedField",
     "ReceiptExtractionResponse",
     "VinAlternative",
+    "VinDecodeRequest",
+    "VinDecodeResponse",
     "VinExtractionResponse",
 ]

ocr/app/models/schemas.py

@@ -169,3 +169,30 @@ class ManualJobResponse(BaseModel):
     error: Optional[str] = None
 
     model_config = {"populate_by_name": True}
+
+
+class VinDecodeRequest(BaseModel):
+    """Request body for VIN decode endpoint."""
+
+    vin: str
+
+
+class VinDecodeResponse(BaseModel):
+    """Response from VIN decode endpoint."""
+
+    success: bool
+    vin: str
+    year: Optional[int] = None
+    make: Optional[str] = None
+    model: Optional[str] = None
+    trim_level: Optional[str] = Field(default=None, alias="trimLevel")
+    body_type: Optional[str] = Field(default=None, alias="bodyType")
+    drive_type: Optional[str] = Field(default=None, alias="driveType")
+    fuel_type: Optional[str] = Field(default=None, alias="fuelType")
+    engine: Optional[str] = None
+    transmission: Optional[str] = None
+    confidence: float = Field(ge=0.0, le=1.0)
+    processing_time_ms: int = Field(alias="processingTimeMs")
+    error: Optional[str] = None
+
+    model_config = {"populate_by_name": True}

ocr/app/routers/__init__.py

@@ -1,5 +1,6 @@
 """OCR API routers."""
+from .decode import router as decode_router
 from .extract import router as extract_router
 from .jobs import router as jobs_router
 
-__all__ = ["extract_router", "jobs_router"]
+__all__ = ["decode_router", "extract_router", "jobs_router"]

ocr/app/routers/decode.py

@@ -0,0 +1,67 @@
+"""VIN decode router - Gemini-powered VIN string decoding."""
+import logging
+import re
+import time
+
+from fastapi import APIRouter, HTTPException
+
+from app.engines.gemini_engine import (
+    GeminiEngine,
+    GeminiProcessingError,
+    GeminiUnavailableError,
+)
+from app.models import VinDecodeRequest, VinDecodeResponse
+
+logger = logging.getLogger(__name__)
+
+router = APIRouter(prefix="/decode", tags=["decode"])
+
+_VIN_REGEX = re.compile(r"^[A-HJ-NPR-Z0-9]{17}$")
+
+# Shared engine instance (lazy init on first request)
+_gemini_engine = GeminiEngine()
+
+
+@router.post("/vin", response_model=VinDecodeResponse)
+async def decode_vin(request: VinDecodeRequest) -> VinDecodeResponse:
+    """Decode a VIN string into structured vehicle data using Gemini.
+
+    Accepts a 17-character VIN and returns year, make, model, trim, etc.
+    """
+    vin = request.vin.upper().strip()
+
+    if not _VIN_REGEX.match(vin):
+        raise HTTPException(
+            status_code=400,
+            detail=f"Invalid VIN format: must be 17 alphanumeric characters (excluding I, O, Q). Got: {vin}",
+        )
+
+    start_ms = time.monotonic_ns() // 1_000_000
+
+    try:
+        result = _gemini_engine.decode_vin(vin)
+    except GeminiUnavailableError as exc:
+        logger.error("Gemini unavailable for VIN decode: %s", exc)
+        raise HTTPException(status_code=503, detail=str(exc)) from exc
+    except GeminiProcessingError as exc:
+        logger.error("Gemini processing error for VIN %s: %s", vin, exc)
+        raise HTTPException(status_code=422, detail=str(exc)) from exc
+
+    elapsed_ms = (time.monotonic_ns() // 1_000_000) - start_ms
+
+    return VinDecodeResponse(
+        success=True,
+        vin=vin,
+        year=result.year,
+        make=result.make,
+        model=result.model,
+        trimLevel=result.trim_level,
+        bodyType=result.body_type,
+        driveType=result.drive_type,
+        fuelType=result.fuel_type,
+        engine=result.engine,
+        transmission=result.transmission,
+        confidence=result.confidence,
+        processingTimeMs=elapsed_ms,
+        error=None,
+    )

ocr/tests/test_vin_decode.py

@@ -0,0 +1,199 @@
+"""Tests for the VIN decode endpoint (POST /decode/vin).
+
+Covers: valid VIN returns 200 with correct response shape,
+invalid VIN format returns 400, Gemini unavailable returns 503,
+and Gemini processing error returns 422.
+All GeminiEngine calls are mocked.
+"""
+
+from unittest.mock import MagicMock, patch
+
+import pytest
+from fastapi.testclient import TestClient
+
+from app.engines.gemini_engine import (
+    GeminiProcessingError,
+    GeminiUnavailableError,
+    VinDecodeResult,
+)
+from app.main import app
+
+client = TestClient(app)
+
+# A valid 17-character VIN (no I, O, Q)
+_VALID_VIN = "1HGBH41JXMN109186"
+
+_FULL_RESULT = VinDecodeResult(
+    year=2021,
+    make="Honda",
+    model="Civic",
+    trim_level="EX",
+    body_type="Sedan",
+    drive_type="FWD",
+    fuel_type="Gasoline",
+    engine="2.0L I4",
+    transmission="CVT",
+    confidence=0.95,
+)
+
+
+# --- Valid VIN ---
+
+
+class TestDecodeVinSuccess:
+    """Verify successful VIN decode returns 200 with correct response shape."""
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_valid_vin_returns_200(self, mock_engine):
+        """Normal: Valid VIN returns 200 with all vehicle fields populated."""
+        mock_engine.decode_vin.return_value = _FULL_RESULT
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN})
+
+        assert response.status_code == 200
+        data = response.json()
+        assert data["success"] is True
+        assert data["vin"] == _VALID_VIN
+        assert data["year"] == 2021
+        assert data["make"] == "Honda"
+        assert data["model"] == "Civic"
+        assert data["trimLevel"] == "EX"
+        assert data["bodyType"] == "Sedan"
+        assert data["driveType"] == "FWD"
+        assert data["fuelType"] == "Gasoline"
+        assert data["engine"] == "2.0L I4"
+        assert data["transmission"] == "CVT"
+        assert data["confidence"] == 0.95
+        assert "processingTimeMs" in data
+        assert data["error"] is None
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_vin_uppercased_before_decode(self, mock_engine):
+        """VIN submitted in lowercase is normalised to uppercase before decoding."""
+        mock_engine.decode_vin.return_value = _FULL_RESULT
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN.lower()})
+
+        assert response.status_code == 200
+        data = response.json()
+        assert data["vin"] == _VALID_VIN
+        mock_engine.decode_vin.assert_called_once_with(_VALID_VIN)
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_nullable_fields_allowed(self, mock_engine):
+        """Edge: VIN decode with only confidence set returns valid response."""
+        mock_engine.decode_vin.return_value = VinDecodeResult(confidence=0.3)
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN})
+
+        assert response.status_code == 200
+        data = response.json()
+        assert data["success"] is True
+        assert data["year"] is None
+        assert data["make"] is None
+        assert data["confidence"] == 0.3
+
+
+# --- Invalid VIN format ---
+
+
+class TestDecodeVinValidation:
+    """Verify invalid VIN formats return 400."""
+
+    def test_too_short_vin_returns_400(self):
+        """VIN shorter than 17 characters is rejected."""
+        response = client.post("/decode/vin", json={"vin": "1HGBH41JXM"})
+
+        assert response.status_code == 400
+        assert "Invalid VIN format" in response.json()["detail"]
+
+    def test_too_long_vin_returns_400(self):
+        """VIN longer than 17 characters is rejected."""
+        response = client.post("/decode/vin", json={"vin": "1HGBH41JXMN109186X"})
+
+        assert response.status_code == 400
+
+    def test_vin_with_letter_i_returns_400(self):
+        """VIN containing the letter I (invalid character) is rejected."""
+        # Replace position 0 with I to create invalid VIN
+        invalid_vin = "IHGBH41JXMN109186"
+        response = client.post("/decode/vin", json={"vin": invalid_vin})
+
+        assert response.status_code == 400
+        assert "Invalid VIN format" in response.json()["detail"]
+
+    def test_vin_with_letter_o_returns_400(self):
+        """VIN containing the letter O (invalid character) is rejected."""
+        invalid_vin = "OHGBH41JXMN109186"
+        response = client.post("/decode/vin", json={"vin": invalid_vin})
+
+        assert response.status_code == 400
+
+    def test_vin_with_letter_q_returns_400(self):
+        """VIN containing the letter Q (invalid character) is rejected."""
+        invalid_vin = "QHGBH41JXMN109186"
+        response = client.post("/decode/vin", json={"vin": invalid_vin})
+
+        assert response.status_code == 400
+
+    def test_empty_vin_returns_400(self):
+        """Empty VIN string is rejected."""
+        response = client.post("/decode/vin", json={"vin": ""})
+
+        assert response.status_code == 400
+
+    def test_vin_with_special_chars_returns_400(self):
+        """VIN containing special characters is rejected."""
+        response = client.post("/decode/vin", json={"vin": "1HGBH41J-MN109186"})
+
+        assert response.status_code == 400
+
+
+# --- Gemini unavailable ---
+
+
+class TestDecodeVinGeminiUnavailable:
+    """Verify Gemini service unavailability returns 503."""
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_gemini_unavailable_returns_503(self, mock_engine):
+        """When Gemini cannot be initialized, endpoint returns 503."""
+        mock_engine.decode_vin.side_effect = GeminiUnavailableError(
+            "Google credential config not found"
+        )
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN})
+
+        assert response.status_code == 503
+        assert "Google credential config not found" in response.json()["detail"]
+
+
+# --- Gemini processing error ---
+
+
+class TestDecodeVinGeminiProcessingError:
+    """Verify Gemini processing failures return 422."""
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_gemini_processing_error_returns_422(self, mock_engine):
+        """When Gemini returns invalid output, endpoint returns 422."""
+        mock_engine.decode_vin.side_effect = GeminiProcessingError(
+            "Gemini returned invalid JSON for VIN decode: ..."
+        )
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN})
+
+        assert response.status_code == 422
+        assert "Gemini returned invalid JSON" in response.json()["detail"]
+
+    @patch("app.routers.decode._gemini_engine")
+    def test_gemini_api_failure_returns_422(self, mock_engine):
+        """When Gemini API call fails at runtime, endpoint returns 422."""
+        mock_engine.decode_vin.side_effect = GeminiProcessingError(
+            "Gemini VIN decode failed: API quota exceeded"
+        )
+
+        response = client.post("/decode/vin", json={"vin": _VALID_VIN})
+
+        assert response.status_code == 422
+        assert "Gemini VIN decode failed" in response.json()["detail"]