Perfect Delivery Inspection (PDI) (GROUP 00, NO. 01-04)

THE TECHNICIAN'S ROLE

The impact you have on the Volkswagen customer is immense. You play a vital role in delivering a perfect Volkswagen to our customers. The delivery process is exciting for our customers. Taking ownership of a vehicle that is clean, problem free and performs as expected goes a long way in customer satisfaction. You not only have a direct impact on delivering a perfect vehicle, but also your attention to detail will give your Volkswagen customer a positive experience about his or her new car far beyond that first day of delivery. By thoroughly performing the PDI and following up on any concerns, you are not only meeting or exceeding your customer's expectations, you are also helping eliminate any buyer's remorse - that feeling of anxiety people get after making a large or important purchase.

Your Fixed Operations Manager (FOM) will visit your dealership to help with the perfect delivery process. If you have any frustrations with your part in the delivery process at your dealership, this is an opportunity to suggest process improvements.

Your FOM is available to help you with this as well. Additional tools available to help you also are part of your certification process through Literature, VWwebsource.com and Max Broadcasts.

Using the Technician's Perfect Delivery Inspection Checklist, Literature Number W42 552 502 84, ensure a "perfect" vehicle by completing a series of checks in eight areas:

1. - Mechanical inspection Under Hood Checks (cold engine)
2. - Exterior inspection
3. - Interior inspection
4. - Radio/CD inspection
5. - On Hoist inspection (vehicle on hoist)
6. - Prior to Road Test inspection (minimum five miles)
7. - Road Test inspection
8. - After Road Test inspection
   NOTE: Be sure to fill out the top portion of the checklist and put the key code and radio code on the R.O. Your signature and date on the checklist are essential.

BATTERY

Battery Static Voltage (must be checked before PDI, prior to starting engine!)

• Check battery clamps for tightness.
• Switch headlights on high beam for 15 seconds to remove any surface charge on battery.
  Fig 1: Checking Battery Voltage

  

With all current consumers turned off:

• Using a digital voltmeter, check battery voltage (check on battery posts not on clamps).

If voltage is below 12.5 volts:

• Recharge battery.
• Record battery voltage on check list.
• Secure battery cover after checking battery voltage (when applicable).

WINDSHIELD WASHER

• Fill windshield washer container(s) with washer solvent Part No: ZVW 177 903. Use appropriate solvent for weather conditions in which vehicle will be operated.
  NOTE: Washer solvent concentration can be checked down -40° C using Special Tool No: T10007.
• Operate washer system to force solvent through hoses (displaces water in hoses).

TIRE PRESSURE, CHECKING

• Check and adjust per specifications (on fuel filler flap or passenger side B-pillar).
• Place wheel lock key in lock holder in trunk.

FRONT LICENSE PLATE BRACKET (IF APPLICABLE)

• Where required, install front license plate bracket. If not installed, put on floor in front passenger area and Sales Consultant will hand to customer. Do not leave in luggage compartment (may cause rattle).

EXTERIOR LIGHTS, CHECKING

Verify operation of exterior lights:

Daytime running, front, parking, fog lights, hazard, side marker, license plate, trunk, tail, stop, backup, puddle (if applicable)

HIGH / LOW BEAMS, QUICK FLASH AND FOG LIGHTS, CHECKING

• Activate headlight switch to headlight position (turn knob clockwise) and make following checks:
• Alternate high/low beams (push lever away from steering wheel/pull lever to center position). Verify high beam indicator light is on in instrument panel when in high beam mode.
• Quick flash: Pull lever toward steering wheel and release.
  NOTE: Daytime running lights/headlights come on at slightly lower illumination when car is running. With emergency brake on, daytime running lights should go out.
• Fog lights (if applicable): pull knob out. Verify indicator for fog light in instrument panel is on.

WIPER, FUNCTION

• Operate wiper lever (ignition switch ON) in all modes (verify all modes operate).
• Verify programmability of wiper delays on applicable models (see Owner's Manual for proper operation).

WIPERS, CHECKING ALIGNMENT ANGLE

Temporarily remove transportation wiper blade as follows:

• Lift wiper arm and blade away from windshield.
• Grasp blade as shown and rotate in direction of arrow (towards windshield).
  Fig 2: Grasping/Rotating Wiper Blade

  
• Rotate blade in opposite direction (black arrow), then carefully slide blade off wiper arm.
  Fig 3: Removing Blade Fron Wiper Arm

  
• Install tool 3358B on wiper arm and check for proper wiper arm alignment to windshield.
• Adjust angle if necessary (see VESIS, Maintenance Group or Electrical Group 92, "Wiper blade contact angle, checking and adjusting for procedure and specifications).
  NOTE: If wiper arm/blade alignment is incorrect, chattering and/or streaking will occur.
  Fig 4: Checking Proper Wiper Arm Alignment To Windshield

  

WIPERS, CHECKING PARK POSITION

• Temporarily install original equipment wiper blades located in trunk.
• Check for proper wiper blade park position to windshield and/or rear glass.
• Adjust if necessary (see VESIS, Maintenance Group or Electrical Group 92, "Wiper blades, checking and adjusting for procedure and specifications).
• Reinstall transportation blades.
  • Original equipment wiper blades must be placed in trunk (to be installed at time of delivery.
    Fig 5: Checking Proper Wiper Blade Park Position

    

WASHER JETS, FUNCTION (ALL EXCEPT EUROVAN)

• Front: Pull lever back and hold; release; fluid stops and wipers continue for 4 seconds.
• Rear: Push lever all the way forward, washer and wiper will operate as long as lever is held in this position. Release lever and wiper will continue for 4 seconds.

WASHER JETS, FUNCTION (EUROVAN)

• Pull lever back and hold, release; fluid stops, wipers continue for four to six seconds.
• Rear window: Push lever forward and hold, release; fluid stops, wipers continue for four to six seconds.
• Push in button on end of lever for rear wiper intermittent mode (six second interval).

WASHER JETS, AIMING

• Check spray pattern of washers to the windshield and/or rear glass.
• If necessary, adjust washer spray jets with special tool 3125A. (see VESIS for procedure and specifications).

CONVERTIBLE TOP

• Check fit and function (see Owner's Manual).

FUSES

• Check for installation of all fuses (ensure fuse panel door snaps into place).

For Golf and GTI only:

• Look for fuses 14 (red, 10 amp., interior/door lights) and 42 (yellow, 25 amp., radio) in red compartment next to 12V outlet (removed to reduce consumption of current during vehicle transport).
• Install one or both fuses as necessary.
  Fig 6: Checking Installation Of Fuses

  

INSTRUMENT PANEL / GAUGES AND WARNING LIGHTS, CHECKING

Ensure the following warning and indicator lights illuminate when key is ON, and go out after the engine is started:

Fig 7: Warning And Indicator Lights Locations

CENTRAL LOCKING SYSTEM/REMOTE FUNCTIONS

Check operation of central locking system:

1. Turning key in driver's door twice unlocks the entire vehicle.
2. Turning key in rear lid once unlocks only the rear lid.
3. Turning key twice in rear lid unlocks entire vehicle.

• Verify that convenience close/open functions are working (if applicable).
• With windows and sunroof open, turn key to lock position and hold until closed.
• With windows closed, turn key to unlock position and hold till open (windows only).
• Verify that all remote control (keyless entry) functions operate correctly (if applicable).
• Verify that rear lid and fuel filler flap release buttons function correctly. Use key to verify locking of rear lid for valet use (Passat only).

IMMOBILIZER ANTI-THEFT DEVICE

• Verify that all keys start engine and allow it to run for more than five seconds. Also verify that immobilizer light in instrument cluster illuminates briefly, then goes out (when applicable, see Owner's Manual).
• If necessary, program key(s) according to VESIS or VAS 5051 Guided Fault Finding.
• Interrogate immobilizer module to retrieve 14 digit code and record on PDI checklist.

SEAT MEMORY

• Initialize memory (if applicable). See VESIS for procedure.

RADIO FREQUENCY REMOTE CONTROL, CODING

• If necessary, code remote control(s) (refer to VESIS Body On Board Diagnostic  as different models have different procedures).

ANTI-THEFT ALARM SYSTEM (IF APPLICABLE)

System is automatically armed/disarmed whenever doors or rear lid are locked or unlocked by key or remote control (flashing light-emitting diode on window sill and a single beep indicates that system is armed).

• Open driver's window.
• Lock door by using key and wait 30 seconds.
• Open door by reaching inside window.

• Alarm should sound, indicating proper operation.

POWER WINDOWS (IF APPLICABLE)

• Check operation of all four power windows by operating each window switch at each location (windows should travel fully in each direction without binding).
• Check one touch down feature of front windows by pushing/releasing switch in down mode.
• Check one touch up feature of front windows by pulling/releasing switch in up mode.
• Check stop feature by momentarily pushing switch while window is going down.
• Check pinch protection of all four windows.
  NOTE: Do not use your hand to check pinch protection, use a wood pencil.

INTERIOR LIGHTS

• Verify operation of the following interior lights (as applicable): Dome, front reading, rear reading, luggage compartment.

CLOCK

• Check operation and set to local time.

RADIO CODE/RADIO RED LED OPERATION

Refer to Sound System booklet for radio theft-coding procedures.

• Each radio has a factory assigned theft code. The code sticker can be found in the spare tire well. (If the code cannot be found, check VESIS for correct retrieval procedures).
• Red LED light does not function until radio is theft-coded.

• After radio has been theft-coded, ensure that red LED light on face of radio blinks when key is removed from ignition.
• Attach radio sticker with serial number and code number to radio card.

SOUND SYSTEM OPERATION

• Turn radio ON and check each function.
• Set all station select buttons to strong local stations on both AM and FM bands.

For Premium 6 radios:

• Press Auto Store (AS) button while in FM band to automatically set the strongest FM stations. Change to AM band and then press the (AS) button again to set the strongest AM stations.

For all radios:

• Using a cassette, check for proper cassette player operation.
• Check for correct operation of CD player in-dash or in luggage compartment (if applicable).
• Check for proper speaker sound performance. Adjust BALANCE and FADE to each speaker to verify its operation (set Balance/Fader control to center detent).
• Verify BASS, TREBLE and MID functions operate.
• Verify that radio and CD operate with key removed and using POWER button. (operates for approximately 60 minutes.)
• Turn ignition key ON and ensure that last function is operating (radio or CD) when powered up.
• Check steering wheel controls (if applicable).

FLUID LEAKS

• Inspect all components for leaks including:

  Transmission, radiator, engine, brake system, steering rack/lines and hoses, oil coolers, fuel lines and connections.

INTRODUCTION

The road test is the most important part of the Perfect Delivery Inspection process.

A proper road test course should consist of a variety of road conditions. The road conditions should allow you to evaluate brakes, steering suspension, acceleration and deceleration. A five mile (eight kilometer) road test should be sufficient and should consist of both highway (50-60mph / 80-90 kmh) and city driving conditions. In addition to component and system checks, listen for squeaks, rattles and abnormal sounds. Any defects must be corrected before the vehicle is delivered to the customer.

INTERIOR/EXTERIOR REAR VIEW MIRROR, OPERATION

• Check interior mirror for correct mounting and that day/night lever is operational.
• Check auto dimming by covering front sensor with your hand and shining light on rear sensor (if applicable).
• Check operation of both manual side view mirrors or switch ignition ON and check entire range of both power side view mirrors.
• Check folding function of side view mirrors (if applicable).

DOOR LOCKS

Child Safety Rear Door Locks

• With locking knob in up position, move slot in direction of arrow using a key. Door should open only from exterior.
• Move slot in opposite direction. Doors should now open from inside or outside.
• Check operation of interior door lock switch.

REAR LID AND FUEL FILLER FLAP RELEASE SWITCHES

• Verify that these switches function properly (if applicable).

POWER SUNROOF

Verify correct operation (if applicable):

• Tilt (if equipped)
• Opening /closing
• Sun shade operation

• Check pinch protection in sunroof. Do not use your hand to check pinch protection, use a wood pencil.
• During road test, set sunroof on "comfort setting" to test.

REAR SUN SHADE, IF APPLICABLE

• Pull out sun shade and insert into hooks, remove from hooks and allow sun shade to retract.

HORN

• With ignition key ON, operate horn.

ENGINE PERFORMANCE - ACCELERATION

Cold Starting/Idle Quality

• Check that engine starts immediately when cold and idles smoothly.
• Test drive vehicle for at least 10 minutes.

While test driving:

• Coolant temperature must be over 176° F (80° C) for at least 3 minutes.

• At engine speed over 4,600 RPM, press gas pedal briefly all the way down.
• In 4th gear, starting from approximately 30 MPH (48 km/h), accelerate for 4 seconds with gas pedal pushed halfway down.
• While driving, listen for abnormal noises; monitor warning lights and gauges.
• Check for engine misfire, stumbling, hesitation or excessive exhaust odors.

AUTOMATIC SHIFT LOCK

• In the "N" position, with ignition key ON, wait approximately two seconds. Then, ensure selector lever cannot be moved in either direction until brake pedal is depressed.
• Depress brake pedal and ensure that starter motor operates only in "P" and "N".

AUTOMATIC TRANSMISSION, SHIFT MODES AND KICKDOWN

• Check selector lever for proper operation.
• Check for proper upshift points.
• Check for proper kickdown operation.
• Check Tiptronic(R) transmission operation (Passat only).

MANUAL TRANSMISSION, GEARSHIFT MECHANISM AND CLUTCH

• Check position of gearshift knob (shift pattern on top of knob should align with center line of vehicle).
• Verify that each gear change is smooth and quiet (because transmission is new, it is likely to have a firm shift, but there should not be excessive sound during or after shifting gears).
• Check clutch for smooth operation and that no chatter or vibration exists.
• Verify clutch-start interlock function by shifting into neutral and trying to start vehicle with and without depressing clutch pedal (should only start with clutch pedal fully depressed).

BRAKE SYSTEM AND PARKING BRAKE

• Check brake pedal for smooth movement and depressed height.
• Accelerate to 20 MPH, apply brakes lightly and bring vehicle to a gradual stop, then accelerate to 30 MPH, apply brakes lightly and bring vehicle to a gradual stop. Repeat this procedure to speeds of 40, 50 and 60 MPH if possible (this process will heat the brake pads gradually without creating "Hot Spots" or "Hard Spots" in brake pads).
• Check holding ability of parking brake by parking on an incline and applying the parking brake, then place transmission in the "N" position (vehicle should not roll while parking brake is engaged).
• Adjust parking brake if necessary.
• Check ABS operation (if applicable).

STEERING WHEEL ADJUSTMENTS, ALIGNMENT, RETURN AND PULL

• Check steering wheel position when driving straight ahead (steering wheel should be centered).
• Check that vehicle does not wander or pull to one side during straight-ahead driving.
• Ensure that steering wheel returns to center position after making 90 degree right and left turns.

CRUISE CONTROL (IF APPLICABLE)

Verify correct operation of cruise control.

• Cruise control ON: Slide button to ON, cruise functions are operational above 20 MPH (30 km/h).

• Set speed: accelerate to desired speed, press SET, or press and hold SET until desired speed is achieved.
• Cancel: Tap brake or clutch pedal or slide button to OFF.
• Return to preset speed (after braking): Slide button to left to RES.
• Check steering wheel controls (if applicable).

UNUSUAL NOISES/VIBRATIONS

• Drive vehicle at highway speed and check for vibration or shimmy (drive vehicle on a smooth asphalt-surfaced road).
• Check entire vehicle for squeaks, rattles, wind noise and unusual vibrations that the customer might consider unacceptable (be sure that all windows, doors and sunroof (if applicable) are closed.
• Check noise level with sunroof switch in "comfort position".
  NOTE: DO NOT confuse road noise with vehicle noise.
• If in doubt, drive on a different surface, and check if noise stops.

CLIMATE CONTROL / AIR CONDITIONING / HEATER OPERATION

• Check manual HVAC for heating, cooling and proper air direction.

CLIMAATRONIC (IF APPLICABLE)

Verify that all functions and displays work properly. Check for proper location and temperature of air output.

Fig 10: CLIMAatronic Control Locations

• Press AUTO button -1-.
• Press red -2- or blue -3-, to raise or lower temperature setting.
• Set temperature to HI by pressing/holding button -2- (check for warm air output).
• Set temperature to LO by pressing/holding button -3- (check for cold air output).
• Press ECON button -4-, press again (listen for compressor to disengage / engage).
• Press button -5-, check for defrost vent output.
• Press button -6- or -7-, to lower or raise fan speed.
• Press button -8-, check center and outboard dash vent outputs.
• Press button -9-, check footwell vent output.
• Press button -10-, ensure that air recirculation door closes and opens, also check for unusual sounds.
• Adjust temperature to several settings; ensure that output air and fan speed change accordingly.
• Set temperature scale correct for market (Fahrenheit or Centigrade): Press and hold ECON and then press AUTO.

INVENTORY MAINTENANCE STICKER (IF APPLICABLE)

• Affix Inventory Maintenance sticker to inside of windshield glass so that it may be easily seen from outside of vehicle.

1. Sticker should indicate month when next Inventory Maintenance is due.

AIRBAG WARNING TRIANGLE

• Ensure presence of triangle affixed to inside of windshield.