General PDI Procedures (2006 Models) (TSB-05-00-001)

Performance Tracking

The Mitsubishi PK (Power Katalyst) SSI System tracks dealership performance in delivering new vehicles that are clean, undamaged, and technically up to standard. These data are updated daily, through the Mitsubishi Dealer Link (MDL).

BEFORE YOU START

Make sure the following information is recorded in the proper spaces on the PDI Worksheet

• Vehicle Identification Number (VIN)
• Model
• Model Year
• Repair order number
• Dealer stock number
• Ignition key code
• Wheel lock code
  NOTE: No 2006 models have the Immobilizer Override feature.

A. VEHICLE READINESS

Before you start the inspection, retrieve the wheel covers, license plate bracket, and radio antenna, and any other shipped loose items from the trunk as applicable.

1. Engage the IOD connector.  On most vehicles, the IOD connector is in the relay box under the hood. Make sure that all doors and trunk/hatch are closed, and the ignition switch is off when engaging the IOD connector.
2. Start the engine - cold start engine performance.  The engine should start quickly, idle smoothly and should not have any hesitation or unusual noise when accelerated.
3. Install all shipped loose items (floor mats, antenna masts, wheel covers, etc.) 
4. Refer to MEDIC, your Dealer Service Information Binder, or the Mitsubishi Dealer Link for any general or model-specific PDI TSB's. Be sure all instructions on the TSB's are performed. 

B. INTERIOR - FUNCTIONAL OPERATION

1. Check WINDOW, SEAT ADJUSTMENT, AND SEAT BELT operation. 

   WINDOWS: Check for proper window tracking, complete up and down, and proper sealing.

   NOTE: On vehicles with power windows, check the lockout and AUTO-down functions.

   SEAT ADJUSTMENT AND SEAT BELT/HEAD RESTRAINT OPERATION.

   1. Make sure the seat backs for driver and passenger adjust and lock in all positions.
   2. Check that the seat track adjuster operates and locks throughout its entire travel (front seats).

      Leave seat height adjuster (if equipped) in the lowest position for maximum head room.

   3. Check power seat operation (if equipped)
   4. Check HEAD RESTRAINTS

      Ensure head restraints are properly installed. Inspect the height adjustment for ease of operation.

   5. Check ALL SEAT BELTS for condition and operation.
      • Inspect all seat belts and harnesses to ensure they connect and hold properly.
      • Inspect the condition of the seat belts and anchors.
      • Inspect for proper seat belt retraction
      • Check that safety labels regarding use of seat belts and air bags are in place.
      • Check heated seat operation (if equipped).
2. Check SUNROOF or CONVERTIBLE TOP operation (if equipped).  Make sure all function controls work properly. Make sure the sunroof closes tightly, and that the tilt-up feature (if equipped) works. Open and close the sunroof a couple of times to make sure the timing of the functions works properly. On convertibles, make sure all windows lower automatically when opening and closing the top. Check convertible top latch operation.
   NOTE: If adjustments are required, refer to the appropriate service manual procedures and submit a warranty claim for the adjustment.
3. INTERIOR AND INSTRUMENT PANEL LIGHTS 

   Check that all interior lights operate:

   • Dome light(s)
   • Map light(s)
   • Vanity mirror light(s)
   • Instrument panel illumination and dimmer function
   • Glove box light
   • Door courtesy lights
   • Luggage area/trunk light
     NOTE: Leave the instrument panel illumination on the brightest position. Place the dome light switch in the position where the light is on when the door is open and off when the door is closed.
4. INSIDE AND OUTSIDE MIRRORS.  Check and adjust the exterior mirrors. Make sure the inside rear view mirror holds its adjustment. Make sure the anti-glare function operates properly.
5. HORN.  Make sure all horn buttons are functional.
6. CIGARETTE LIGHTER (if equipped) / AUXILIARY ACCESSORY SOCKET(S) (if equipped).  Push in the lighter. After it pops out, make sure the element is hot. Check the auxiliary accessory sockets (if equipped) for proper operation.
7. Turn on the REAR WINDOW DEFOGGER  so it will be warmed up when you check it later.
8. SET CLOCK AND ALL RADIO STATION PRESETS.  Set the clock to the correct time. Set ALL "AM", "FM1", & "FM2" preset buttons to a variety of strong local stations.
9. AUDIO SYSTEM OPERATION (INCLUDING ANTENNA OPERATION) and VIDEO ENTERTAINMENT SYSTEM (VES) OPERATION (if equipped)  .

   Check the radio  and speakers  operation for:

   • Volume
   • Reception of both AM & FM stations
   • Tone (bass & treble)
   • Balance/Fader Controls
   • CD Player, including CD-changer (if equipped)
   • Rattling or vibrating speakers
   NOTE: Adjust the treble, bass, balance, and fader controls to their center position after radio inspection.

   Check that the automatic antenna  (if equipped) is extended when the radio is on. Also check that the antenna retracts when the radio and/or the key is turned off.

   Check the Video Entertainment System  for:

   • DVD/MP3 player operation
   • Video controls operation
   • Remote control and headphone operation (install batteries if necessary)
10. REAR WINDOW DEFOGGER and HEATED DOOR MIRROR (if equipped).  Check with the engine running (ETACS will not allow operation below generator output of 3.5V).

    Allow time for the defogger and mirror to warm up. Place your hand on the rear window defogger and heated door mirror (if equipped) to make sure it is heating. Be sure to turn off the defogger after checking. Turn the engine off.

C. WALKAROUND INSPECTION

Before starting this section, turn the engine OFF, then turn the ignition switch to the "ON" position and place the transmission selector in "R" (reverse) with the parking brake applied.

1. Check EXTERIOR LIGHTS.  Make sure ALL exterior lights operate properly. Check for chipped or cracked lenses. On vehicles with AUTO-OFF headlights, turn on the headlights and turn the ignition OFF. The headlights, side-marker lights, and taillights should turn off when the driver's door is opened. Be sure to turn ALL lights OFF after completing inspection. Return the transmission selector to "P" (park).
2. REMOTE KEYLESS ENTRY (RKE), THEFT ALARM SYSTEM, ALL DOOR LOCKS, LATCHES, & IMMOBILIZER 

   RKE (if equipped) 

   Check the door and trunk (if equipped) locking and unlocking feature.

   Make sure the key is removed from the ignition. Close all doors and trunk. Press the "lock" buttons once to lock all doors. Pressing the "unlock" button once will unlock the driver's door and pressing it twice unlocks all doors. On remotes with 3 buttons, the third button unlocks the trunk. Press the "trunk" button twice to open the trunk. Press the "Panic" button (if equipped) to test the alarm system. Press again to turn off the panic alarm.

   NOTE: Factory-installed RKE systems have an "answerback" system which can be programmed for various answerback configurations depending on the model and system installed. Make sure the vehicle's answerback function is in the full-function answerback mode where both the horn and lights signal when the doors are locked. Refer to the vehicle owner's manual for programming information.

   Theft Alarm (if equipped) 

   1. Lower the driver's window. Remove the key from the ignition switch.
   2. Open the driver's door, lock all the doors using the power door lock switch, and close the door. The security light on the instrument panel will be lit for about 20 seconds and then go out (light will be lit on the Montero after 20 seconds then blink continuously until unlocked by key or RKE).
   3. Reach through the open window, manually unlock the door, and then open it. The alarm horn should sound and the headlights should flash.
   4. To deactivate the alarm, insert the key into the door or trunk key slot and turn the key.
   5. Repeat steps a. through d. on the front passenger's door and lock.
   6. Repeat steps a. through d. using the trunk remote release and trunk lock.
   7. Repeat steps a. through d. on the hood release

   Door Locks & Latches 

   Close each door to check the latch mechanism. If adjustments are required, refer to the appropriate service manual. Submit a warranty claim for any adjustment performed.

   Child Safety Door Lock Operation 

   The rear door should not open from the inside when the lever (located on the inside rear area of the door) is in the lock position.

   NOTE: Set the lock to the unlock or "FREE" position when you are finished checking its operation.

   Fuel Filler Door 

   For vehicles with remote release, pull the release lever and make sure that the door opens. Close the door and verify the door latches properly.

   For vehicles without remote release, make sure the fuel door opens and closes properly.

   Immobilizer (if equipped) 

   Insert ALL keys into the ignition switch and make sure that ALL keys will start the engine without stalling. If the vehicle starts, then stalls, one or more of the keys may not have been registered, or there may be an immobilizer system problem. Refer to the service manual for diagnosis procedures, and use MEDIC  and/or the Mitsubishi Dealer Link (MDL) Technical Information/Training extranet site to search for TSBs relating to Immobilizer system subjects and Immobilizer key registration policies and procedures.

3. TRUNK/HATCH/LIFTGATE, TRUNK LIGHT AND TRUNK/CARGO AREA TRIM APPEARANCE Check for trunk/hatch/liftgate closing quality (make sure it closes easily)  and fit. Fit should be uniform.

   Check the operation of the remote trunk release.

   Verify trunk light comes on and all trim is installed properly.

4. Check REAR WINDOW WASHER FLUID (if equipped) 

   Top off the fluid if necessary

5. SPARE TIRE PRESSURE, WHEELS, JACK, TOOLS 

   Spare Tire Pressure 

   Some models require removal of the spare tire for tire pressure adjustment. Make sure the tire hold down is secure.

   Wheels 

   On Eclipse vehicles equipped with 18" wheels, remove the foam tape from the inside wheel weights.

   Jack & Tools 

   Check for jack and tools. On cars, the tools and jack are in the trunk. Refer to model-specific PDI related TSBs, if any, for more information concerning jack and tool location.

6. EMERGENCY INSIDE TRUNK RELEASE HANDLE 

   Check the operation of the T-shaped yellow emergency inside trunk release handle. Open the trunk lid and trip the latch by pushing up on the catch with the shaft of a screwdriver to simulate trunk closure. Remove the screwdriver with the latch in the closed position, and verify emergency trunk release by pulling the yellow handle. Then be sure to secure the handle into its holder with the Velcro. For more information about the Emergency Inside Trunk Release, refer to the vehicle's owner's manual.

D. UNDERHOOD

IMPORTANT: Use fender covers to protect the vehicle body. 

1. Check BATTERY Charge.  Check that the battery, cable terminals, and additional wires attached to the positive terminal are tight and that the battery is secure in the tray.

   Check the battery to see if it is fully charged (12.4 v). If charging is necessary, follow the service manual procedures and recharge the battery. Remove and discard the battery maintenance tag (if equipped).

2. BRAKE, CLUTCH, AND POWER STEERING FLUID 
   1. Check the fluid levels on the scale on the plastic reservoir of both master cylinders (brake and clutch). They should both be at the FULL mark. Fill if necessary.
      NOTE: Use either DOT 3 or DOT 4 brake fluid (preferably genuine Mitsubishi BRAKE FLUID, part number MZ311987). Do not add fluid to the ABS unit reservoir.
   2. Check power steering fluid. It should be at the proper level on the dipstick or on the scale on the plastic reservoir. Use genuine Mitsubishi Power Steering Fluid, part number ACH1ZC1X04.
3. Check COOLANT, WINDSHIELD WASHER FLUID, AND HEADLIGHT WASHER FLUID (Montero Only) 

   Check these fluid levels. Add fluid if necessary. For COOLANT, use a 50/50 mixture of water and ethylene-glycol antifreeze (genuine Mitsubishi COOLANT, part number MZ311986).

   Use windshield-washer fluid (genuine Mitsubishi WASHER FLUID, part number MZ311988) for the windshield washer and headlight washer reservoir.

4. ENGINE OIL 

   Check engine oil level. If oil is needed, check the appropriate Service Manual for correct grade of oil.

5. EMISSION CONTROL EQUIPMENT 

   The Environment Protection Agency (EPA) requires this inspection  .

   Using the underhood label as a guide, verify all emission control equipment is installed.

E. UNDER VEHICLE

Every vehicle which passes through PDI should be put on a rack for under vehicle inspection. Refer to the appropriate service manual for lift points for the vehicle being inspected.

1. Remove the BRAKE ROTOR PROTECTION (bags/covers)  [if equipped].
2. FLUID LEAKAGE 
   1. Check for leaks from any engine components, transmission, fuel lines, coolant hoses, power steering lines, and A/C lines (if equipped).
   2. Check lines for twists, kinks, and proper routing.
3. TIRE PRESSURE AND INSPECT TIRES FOR DAMAGE 

   Adjust tire pressure to specifications. For tire pressure specifications, refer to the tire pressure label on the driver's side B-pillar.

   IMPORTANT: On some models, the factory over-inflates the tires by 50% to prevent flat spots in shipping. It is critical to adjust tire pressures to the proper specifications. 

   Check all tires for damage such as cuts, foreign objects in the tire, or any other imperfections.

   Remove the tire pressure and tire balance decals from each tire if either or both decals are present.

F. ROAD TEST

Preliminary Road Test Notes 

Vehicles should be at operating temperature prior to performing these tests. Before you conduct the road test, establish a route that you will use on every test. Recommended road test duration is at least 15 minutes.

The PDI road test should be conducted under a variety of different operating and road conditions.

If the vehicle is equipped with air conditioning, place a thermometer in the center vent before beginning your road test. This will be used later to check the air conditioner operation.

Record BEGINNING mileage 

Record the beginning mileage of your road test on the PDI Worksheet.

1. A/T SHIFT INTERLOCK 

   Make sure the shift lever can only be moved when the brake pedal is depressed and the key is in the unlocked position.

2. A/T STARTER INTERLOCK 

   Make sure the engine can be started ONLY when the shift selector is in PARK or NEUTRAL.

3. M/T CLUTCH - STARTER INTERLOCK 

   Make sure the engine will start only when the clutch pedal is depressed.

4. WARNING, INDICATOR LIGHTS AND GAUGES 
   1. Turn the ignition ON. The indicator and warning lights shown in the illustration should be on (as equipped).
   2. Start the engine and verify all indicator lights go out, including the Check Engine light.
      NOTE: The EPA requires that dealers must visually inspect the emission control devices prior to delivery, or, as an alternative, inspect each vehicle for an illuminated malfunction light, and if the light is illuminated, diagnose and correct the malfunction.
   3. The brake warning light should be lit when the parking brake is applied.
   4. Verify that all gauges and lights are working as equipped.
   5. Check the operation of the seat belt warning buzzer and the key reminder buzzer.
      Fig 1: Identifying Warning, Indicator Lights And Gauges

      
5. ELECTRONIC COMPASS (If equipped) 

   Refer to Group 52A in the service manual for electronic compass calibration instructions. Check the compass variance (the difference between the earth's magnetic north and true geographic north poles). If compass variance is not adjusted properly, the compass can give false readings. The electronic compass requires calibration when power is disconnected (removing the battery cable or disconnecting the IOD connector).

6. M/T: Check CLUTCH AND M/T OPERATION 

   Check for proper clutch operation and smooth shifter/transmission operation. Repeatedly shift up and down at least 10 times at idle and at speeds under 40 mph.

7. A/T: Check A/T OPERATION 
   1. From 25 mph, accelerate to full throttle. The transmission should kick down to 1st gear and then shift to the higher gears (For Monteros, start at 15 mph).
   2. Idle for 20 seconds in "N" then shift to "D" then "R" holding at each position for more than 3 seconds.
   3. Check for smooth shifting during normal driving. Then upshift from 1 to 4 with 20% and 30% throttle and decrease to a stop. On Eclipse, Galant, Montero, Endeavor, and Outlander vehicles with Sportronic(tm), slide the shift lever into the "Sport Mode" slot and upshift and downshift to verify proper operation. 
8. 4WD & AWD: Check TRANSFER CASE OPERATION - Montero (4WD) 

   Check for proper engagement and disengagement in the following 4WD modes:

   2H

   4H

   4HLc

   4LLc

   For detailed explanation of the Transfer Case Operation, refer to the Owner's Manual or in-vehicle decal.

9. Check ENGINE PERFORMANCE 
   WARNING: Always follow all traffic laws and safe driving practices.

   Check engine performance under the following conditions. The throttle should be responsive and without hesitation.

   Part Throttle 

   With the vehicle at a constant speed (25-35 mph), engine performance should be smooth and without hesitation.

   Under Load 

   Accelerate to three-quarters throttle. The vehicle should accelerate smoothly, without laboring or hesitation.

   At Cruise 

   With the vehicle at a constant speed (45-55 mph), engine performance should be smooth, without hesitation or surging.

10. Check CRUISE CONTROL 

    The cruise control is operated by a stalk mounted switch on the right side of the steering wheel hub.

    The main control switch is on the end of this stalk.

    Control Functions

    Main -  Energizes and de-energizes the system and turns on the indicator light.

    Set/Coast -  Sets control speed. Also used for reducing the set speed.

    Resume/Accel -  Resumes previously set speed. It also increases the set speed.

    System Operation Check

    1. Accelerate to 30 mph.
    2. Turn on the MAIN switch. Make sure the CRUISE light illuminates.
    3. Activate the SET function to set the vehicle speed. The vehicle speed should hold at 30 mph.
    4. Increase the vehicle speed slightly by activating the RESUME function momentarily.
    5. Check each canceling function by depressing the brake, clutch (MT only), and by activating the CANCEL button.
    6. Resume the set speed by activating the ACC/RESUME button.
       NOTE: The cruise control will not operate below 25 mph.
    7. Turn the cruise control off by pressing the MAIN switch.
11. SQUEAKS, RATTLES, AND WIND NOISE 

    Check for any abnormal noise and vibration during your road test, including driveline, pedal, or steering wheel vibration. On convertibles, close the top during the road test.

    Be sure to close all windows and sunroof and turn off the audio during this inspection. 

12. STEERING OPERATION AND WHEEL ALIGNMENT 

    Make sure the steering wheel is centered when the vehicle is traveling straight ahead.

    The vehicle should track straight on a level surface, without pulling or drifting. If a problem is identified, correct it. Refer to the service manual for adjustment procedures.

13. BRAKE PERFORMANCE AND ABS OPERATION 
    1. Brake performance

       The vehicle should brake smoothly and in a straight line. There should be no abnormal noise or vibration during braking. Brake pedal feel should be firm, not soft or mushy.

    2. ABS operation (if equipped)
       WARNING: Always check that no vehicles are behind you when doing this ABS brake check.

       In a safe location with no other vehicles or objects around, check the operation of the ABS system. During hard braking, the vehicle should come to a controlled, straight stop. You will feel some pedal pulsation and may hear normal sounds from the ABS system.

14. WINDSHIELD WIPER & WASHER OPERATION (front & rear) 

    WINDSHIELD WASHER AIM (front & rear)

    1. Check washer aim, both front & rear (if equipped).
    2. Make any needed adjustments, referring to the service manual. Submit a warranty claim for adjustments performed.

    WINDSHIELD WIPER OPERATION (and also rear if equipped)

    1. Verify correct wiper operation during all speeds. If streaking occurs, clean the wiper blades with a cloth soaked in a mild detergent.
    2. Make sure the wipers park properly.
15. HEATER AND A/C OPERATION (if equipped) 

    Check for proper operation of all modes, air intake selection, and temperature control. Check the fan speed and check for any unusual fan noises.

    Using a thermometer in the center air outlet, check for proper cooling when the air conditioner is operating. Refer to the service manual for temperature specifications or conditions for the particular model. Make sure the air intake control is in the RECIRC position.

16. HOT ENGINE IDLE SPEED WITH A/C ON AND OFF 

    With the engine at operating temperature, check the idle quality with the air conditioning ON and OFF. When finished, leave the air intake door in the FRESH position.

17. Check PARKING BRAKE 

    Park the vehicle on a slight incline and leave the transmission in NEUTRAL. With your foot off the service brake, the parking brake should be able to hold the vehicle.

    NOTE: Count the number of "click" notches it takes to engage the parking brake. If it is more than 8, adjust the parking brake according to service manual procedures.
18. Check ATF 

    With the parking brake applied and the engine running, check automatic transmission fluid level. Add or extract fluid if necessary to ensure level is at the HOT marks on the dipstick.

19. Record the ENDING mileage 

    Record the ending mileage of your road test onto the PDI Worksheet.

20. RECALLS 

    Check the Warranty Superscreen for any open recalls. Make sure any recall affecting a new vehicle is performed before the vehicle is offered for sale. 

FINAL STEP FOR TECHNICAL INSPECTION

Sign and date the Technician's Signature area on the PDI worksheet. Leave the worksheet with the vehicle for the Detail Specialist for the after-PDI detailing.