PDI PROCEDURE REFERENCE
Pre-Delivery Inspection is the 30-60 minute checklist run on every vehicle BEFORE the customer takes delivery (new) or BEFORE the vehicle leaves your shop (used/serviced). Get it wrong, vehicle comes back. Get it right, customer comes back next time.
PDI ZONE SEQUENCE
5 zones. 43 inspection points. Top-down sequence keeps you efficient and the audit clean. Sign off each zone before moving on.
Total: 43 inspection points · ~30-60 min · Sign-off required per zone
PRE-LIFT (DOCS & EXTERIOR)
| Step | Check | Pass criteria |
|---|---|---|
| 1 | VIN match to RO and key fob | VIN on dash, RO, key fob all match. Document. |
| 2 | Body panel walkaround | No dings, scratches, paint chips. Note pre-existing in walkaround sheet. |
| 3 | Trim, badges, mirrors | All present, tight, aligned. |
| 4 | Glass condition | No cracks, chips, or scratches. |
| 5 | Tire condition (visual) | Tread depth, even wear, brand match (no mismatched), pressure check. |
| 6 | Lighting check (operator outside) | Head/tail/turn/brake/reverse/license plate lamp — all working. |
| 7 | Door + trunk + hood operation | Open, close, latch — no sticking. |
| 8 | Wipers + washer spray | Clean wipe pattern, both nozzles spraying. |
INTERIOR (CABIN & CONTROLS)
| Step | Check | Pass criteria |
|---|---|---|
| 9 | Carpet, mats, headliner | Clean, no staining, no tears. |
| 10 | Seats — all adjustments, heaters, memory | Power forward/back/recline + heat/cool work. |
| 11 | Mirrors (power + heat) | Adjust and heat function. |
| 12 | Windows (all positions, auto) | Up/down at each switch, auto-up/down at driver. |
| 13 | Door locks (key fob + manual) | All doors lock/unlock from fob and switches. |
| 14 | Sunroof / moonroof (if equipped) | Full open, tilt, close. No binding. |
| 15 | Stereo, Bluetooth, USB, CarPlay/Android Auto | Pair phone, test all inputs. |
| 16 | HVAC — all modes, all temps, all fan speeds | Full cold, full hot, defrost, vent, floor. |
| 17 | Climate vent output temps | Cold side < 45°F. Heat side > 130°F. |
| 18 | Cruise control, lane departure, adaptive features | Activate each, verify function on test drive. |
| 19 | Backup camera + parking sensors | Image clear, sensors triggering at proper distance. |
| 20 | Dash warning lights at key-on | All bulbs on at key-on then clear at start. NO codes after start. |
UNDERHOOD (ON LIFT OR HOOD UP)
| Step | Check | Pass criteria |
|---|---|---|
| 21 | Engine oil level, condition | Full, correct grade, clean. |
| 22 | Coolant level, condition, type | Full to mark, correct color/type. |
| 23 | Brake fluid level, moisture | Between MIN/MAX. < 2% moisture. |
| 24 | Power steering fluid (if hydraulic) | Between marks. EPS = electric, skip. |
| 25 | Washer fluid | Full. |
| 26 | Battery test (load + voltage) | 12.5V+ rested, > 9.6V cranking under load. |
| 27 | Engine ground clearance / undercover | All shields installed, all bolts tight. |
| 28 | Visible leaks (oil, coolant, ATF, brake) | None. Note even weeping. |
UNDERCAR (LIFT)
| Step | Check | Pass criteria |
|---|---|---|
| 29 | Brake pads, rotors, hoses | Spec per axle. Hoses no cracks/bulges. |
| 30 | Suspension components (shocks, struts, ball joints, tie rods, control arms) | No leaks, no play, intact boots. |
| 31 | CV joint boots + axles | Intact, no grease slung. |
| 32 | Exhaust system mounts, leaks | Mounts intact, no audible leaks. |
| 33 | Driveshaft + U-joints / CV (RWD/AWD) | No play, no rust on joints. |
| 34 | Fuel tank straps + lines | Straps tight, no leaks at lines. |
| 35 | Sway bars + end links | No clunks, bushings intact. |
ROAD TEST (5-10 MIN)
| Step | Check | Pass criteria |
|---|---|---|
| 36 | Cold start, idle | Smooth start, stable idle 700-900 RPM no surge. |
| 37 | Acceleration through gears | Smooth shifts, no flare, no shudder. AT or MT. |
| 38 | Steering — straight tracking | No pull, no wandering. Center within 5° at speed. |
| 39 | Brakes — firm pedal, no pull, no vibration | Even stop, no pulling, no judder at 60→0. |
| 40 | Cabin noises (squeaks, rattles, wind) | None at 30, 50, 70 mph. |
| 41 | Cruise control engages, holds, disengages | Test on flat road. |
| 42 | HVAC at speed (heat AND A/C) | Vent temps within spec, no funny smells. |
| 43 | Reverse, parking | Backup camera, sensors, transmission engagement smooth. |
SIGN-OFF SHEET = LEGAL RECORD
Every PDI sheet should be signed (initialed at each section) by the tech who performed it, then countersigned by the foreman/manager. This is your legal record if the vehicle has a warranty issue 6 months later — the PDI is evidence the vehicle was inspected correctly. Skipping initials = no defense.
When you find issues during PDI: do NOT release the vehicle until repaired. Document the issue, photograph it if relevant, route to the service advisor for customer communication. Releasing a vehicle with known defects = liability.