Service VOLKSWAGEN PASSAT 2015 B8 / 6.G Service Manual

WARNING
Incorrect tire pressures and/or underinflation can cause sudden tire failure, loss of control, collision, serious personal injury or even death.
x When the warning symbol appears in the instrument cluster, stop and inspect the tires.
x Incorrect tire pressure and/or underinflation can cause increased tire wear and can affect the handling of the vehicle and stopping ability.
x Incorrect tire pressures and/or underinflation can also lead to sudden tire failure, includ-ing a blowout and sudden deflation, causing loss of vehicle control.
x The driver is responsible for the correct tire pressures for all tires on the vehicle. The
recommended tire pressure values are listed on a sticker inside the driver door ⇒  Tire infla-
tion pressure inside the fuel filler flap ⇒  Tire inflation pressure.
x The TPMS can only work correctly when all tires on the vehicle are filled to the correct pressure.
x Using incorrect tire pressure values can cause accidents or other damage. Always inflate the tires to the correct specified cold tire pressure values for the tires installed on the vehicle.
x Always maintain correct cold tire inflation pressure so that TPMS can do its job.
x Always inflate tires to the recommended and correct tire pressure before driving off.
x Driving with underinflated tires causes them to flex (bend) more, letting them get too hot, resulting in tread separation, sudden tire failure, and loss of control.
x Excessive speed and/overloading can cause heat build-up, sudden tire failure and loss of control.
x If the tire pressure is too low or too high, the tires will wear prematurely and the vehicle will not handle well.
x If the tire is not “flat” and you do not have to change a wheel immediately, drive carefully and at reduced speed to the nearest service station to check the tire pressure and add air as required.
x When replacing tires or wheel rims on vehicles equipped with TPMS always read and heed
the information and all WARNINGS regarding ⇒  Tires and wheels.
x The Tire Pressure Monitoring System must be recalibrated using the SET button whenever you remove and remount or change any wheel or tire on the vehicle, even if the reinstalled or replacement wheels and tires are identical to those that were removed and even if the tire
pressure does not change ⇒  Tire Pressure Monitoring System (TPMS) and recalibration with the SET button.
WARNING
Improper use of the SET button can cause the TPMS to give false warnings or to give no
warning despite dangerously low tire pressure ⇒  Tire Pressure Monitoring System (TPMS) and recalibration with the SET button.
Underinflation increases fuel consumption and tire wear.
Do not rely solely on the Tire Pressure Monitoring System. Check your tires regularly to make sure they are properly inflated and have no signs of damage, such as punctures, cuts, cracks, and blisters. Remove any objects that become embedded in the tire tread but have not penetrated into the body of tire itself.

x Unleaded fuels for vehicles with catalytic converters may not be available.
x Ultra Low Sulfur Diesel (ULSD) fuel No. 2 that your diesel engine requires may not be available.
x Fuel may have a considerably lower octane rating and may cause engine damage.
x Service may be inadequate due to lack of proper service facilities, tools or testing equipment.
x Replacement parts may not be readily available.
x DVD navigation systems for vehicles built for the United States and Canada will not necessarily work in Europe, and may not work in other countries outside of North America.
NOTICE
Volkswagen is not responsible for mechanical damage that may result from substandard fuel or service or the unavailability of Genuine Volkswagen parts.
x Volkswagen is not responsible if the vehicle does not meet the respective legal require-ments in other countries and continents.
Radio antenna and reception

WARNING
Improperly performed repairs and modifications can cause vehicle damage and malfunctions, and can impair the efficiency of driver assistance systems and the airbag system. This can lead to accidents and severe personal injuries.
x Have repairs and vehicle modifications performed by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.

WARNING
Improper use of the remote start feature can cause fire, burns and other serious injuries.
x Always park the vehicle in a place that is vented to the outdoors and has a continuous exchange of fresh, outside air.
x Only use the remote start feature when no one is around or inside the vehicle.
x Always make sure that you can see the vehicle when the engine is running.
x Never leave children, disabled persons, anyone who cannot help themselves, or pets in the vehicle. The doors are locked when the engine is running with the remote start feature. Vehicle occupants would be trapped in the vehicle in an emergency and rescue from the outside would be delayed.
x Never start the engine if children or animals are inside the vehicle. When the engine is running, electrical equipment including electrical seat adjustment controls can be operated and cause serious injuries.
x Never start the engine or let it run in a garage, in an enclosed or confined area. Engine exhaust contains carbon monoxide, a poisonous, colorless and odorless gas. Carbon mon-oxide can cause dizziness, nausea, unconsciousness and even death.
x Always make sure that the area where the engine runs in the remote start mode is well ventilated. Carbon monoxide in a garage or other enclosed area can cause dizziness, impair the ability to drive, and even result in unconsciousness.
x Never start the engine when the vehicle is covered with a protective cover. Hot vehicle components and exhaust could ignite the protective cover.
x Never start the engine near combustible or explosive materials. The exhaust could ignite flammable materials.
NOTICE
x Do not use the remote start feature if the engine Malfunction Indicator Light (MIL) ⇒  Indica-
tor lights, ⇒  Indicator lights has come on, smoke or unusual smells come from the vehicle, an unusual or unexpected operating condition occurs and the condition has not been diagnosed and corrected. Please see an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
x Remote start is possible when one or more windows are open. Always remember that unau-thorized access to the vehicle through open windows as well as operation of HomeLink®, in-cluding access to your garage or other property, is possible when the engine is running in remote start mode. Always make sure that all of the windows are securely closed to help pre-vent unauthorized access to the vehicle, its features and contents.
Using the remote start feature can increase fuel consumption and drain the vehicle battery.
Use of the remote start feature may be regulated or prohibited in some areas. In some areas you may be required to be able to see the vehicle when it is running in remote start mode. Please inform yourself about state and local requirements that may apply and be sure to follow them when using the remote start feature.
Various vehicle functions, such as the low beam headlights and the windshield wipers, are disabled when the engine is running during a remote start.

Lights up Possible cause Proper response
D
Power steering assist is reduced.
Stop, restart the engine, and drive a short distance. If the yellow warning light does not come on again, you do not need to have the steering system checked. Otherwise, have the steering checked imme-diately by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.
Vehicle battery was disconnected and has been reconnected. Drive a short distance at about 10–12 mph (15–20 km/h).


Flashes Possible cause Proper response
D Electronic steering column lock malfunc-tion.

When the ignition is switched on, several warning and indicator lights come on briefly for a function check. They go out after a few seconds.
WARNING
Failure to heed warning lights and instrument cluster text messages can cause the vehicle to break down in traffic and result in a collision and serious personal injury.
x Never ignore warning lights or text WARNINGS.
x Always stop the vehicle as soon as it is safe to do so.
WARNING
Driving with bad brakes can cause a collision and serious personal injury.
x If the brake warning light "2!+% or H does not go out, or lights up when driving, either the brake fluid level in the reservoir is too low or there is a fault in the brake system. Stop the
vehicle as soon as you can do so safely and get expert assistance ⇒  Brake fluid.
x If the brake warning light "2!+% or H lights up at the same time as the ABS warning light !"3 or J, the ABS may not be working properly. This could cause the rear wheels to lock up rela-tively quickly during braking. Rear wheel brake lock-up can cause loss of vehicle control.
x If you believe the vehicle is safe to drive, drive slowly and very carefully to the nearest authorized Volkswagen dealer, authorized Volkswagen Service Facility, or other qualified workshop and have the brake system inspected. Avoid sudden hard braking and steering.
x If the ABS indicator light !"3 or J does not go out, or if it lights up while driving, the ABS system is not working properly. The vehicle can then be stopped only with the standard brakes (without ABS). You will not have the protection ABS provides. Contact your author-ized Volkswagen dealer or an authorized Volkswagen Service Facility as soon as possible.
x If the symbol "2!+% 7%!2 or I lights up in the instrument cluster display, whether alone or together with a text message, immediately contact an authorized Volkswagen dealer or au-thorized Volkswagen Service Facility to have the brake pads checked and, if necessary, re-placed.
NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.
Parking brake

Fig. 162 Between the front seats: Parking brake.

Brakes coated with road salt also react slower and need longer stopping distances. If there is salt on the roads and you are not braking regularly, brake carefully and gently from time to time to remove any
salt coating from the brake discs and pads ⇒ .
Brake disc corrosion (rust) and dirt build-up on the brake pads are more likely to occur if the vehicle is not driven much or is driven only for short distances with little braking. If the brakes have not been used and there is some rust on the discs, clean the brake discs and pads once in a while by carefully braking a couple of times while driving at relatively high speed to help clean the brake discs and pads.
Make sure nobody is behind you and that you do not endanger yourself or others ⇒ .
Brake system malfunction
If you brake and find that vehicle doesn't brake nearly as well as it used to (sudden increase in stop-ping distance), a brake circuit may have failed. The brake warning light H or "2!+% will come on and a message may appear in the instrument cluster display. If you believe the vehicle is safe to drive, immediately take it to the nearest authorized Volkswagen dealer or authorized Volkswagen Service Facility for repair. Drive slowly and very carefully, allow for the longer stopping distance, and be ready to push longer and harder on the brake pedal to slow the vehicle down.
Brake booster
The brake booster works only when the engine is running. It increases the force on the brakes above and beyond the pressure put on the brake pedal by the driver.
If the brake booster is not working, or if the vehicle has to be towed, you will have to push the brake pedal harder to make up for the lack of booster assistance and the resulting longer stopping distance
⇒ .
WARNING
New brake pads do not provide maximum braking performance.
x New brake pads do not have the best stopping power for the first 200 miles (320 km) and must be “broken in.” You can compensate for the slightly reduced braking force by putting more pressure on the brake pedal.
x Drive with extra care while the new brake pads are being broken in. This reduces the risk of collisions and serious personal injuries due to a loss of control over the vehicle.
x Never follow other vehicles too closely or put yourself into other situations that might require sudden, hard braking, especially when the brake pads have not been broken in.
WARNING
Overheated brakes will reduce the vehicle's stopping power and increase stopping distances considerably.
x When driving downhill, the brakes have to work especially hard and heat up quickly.
x Before driving downhill, especially on hills that are long or steep, always reduce speed and shift into lower gear (manual or automatic transmission). This will let the vehicle use engine braking and reduce the load on the brakes. Otherwise, the brake system could over-heat and possibly fail. Only use the brakes when you need them to slow the vehicle down more or to stop.
x A damaged front spoiler or a non-standard spoiler can reduce airflow to the brakes and make them overheat.

WARNING
Wet brakes or brakes coated with ice or road salt react slower and need longer stopping dis-tances.
x Carefully apply the brakes to test them.
x Always dry brakes and clean off ice and salt coatings with a few cautious brake applica-tions when visibility, weather, road and traffic conditions permit.
WARNING
Driving when the brake booster is not working increases stopping distances and can cause accidents and serious personal injuries.
x Never let the vehicle coast when the engine is switched off.
x If the brake booster is not working (such as when the vehicle is being towed), a lot more pedal force is needed to slow down and stop.
NOTICE
x Never “ride” the brakes by keeping your foot on the brake pedal when you do not want to brake. Constant pressure on the brake pedal can make the brakes overheat. Riding the brakes will substantially reduce braking performance, increase stopping distance, and can cause complete brake system failure.
x Before driving downhill, especially on hills that are long or steep, always reduce speed and shift into lower gear (manual or automatic transmission). This will let the vehicle use engine braking and reduce the load on the brakes. Otherwise, the brake system could overheat and possibly fail. Only use the brakes when you need them to slow the vehicle down more or to stop.
When the front brakes are serviced, you should have the rear brake pads inspected at the same time. The wear of all brake pads should be visually checked regularly. The best way to check for brake pad wear is to have your authorized Volkswagen dealer or authorized Volkswagen Service Facility visually inspect the pads through the openings in the wheel rims or from underneath the vehicle. If necessary, the wheels can be taken off for a more thorough inspection.
Braking assistance systems

Changing brake fluid
Brake fluid must be changed according to the service schedule in your ⇒ Booklet Warranty and
Maintenance. Have the brake fluid checked by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. Refill only with new brake fluid that meets the standards listed above.
WARNING
Brake failure and reduced brake performance can be caused by not having enough brake fluid in the reservoir or by old or incorrect brake fluid.
x Check the brake system and brake fluid level regularly.
x Always change the brake fluid according to the service schedule in your
⇒ Booklet Warranty and Maintenance.
x Hard braking with old brake fluid may cause vapor lock. Vapor lock reduces braking per-formance, increases stopping distances and can even cause total brake failure.
x Always make sure that only the correct brake fluid is used. Only use brake fluid that ex-pressly conforms to VW standard 501 14 or if it is not available, only use a high-quality brake fluid that conforms to U.S. Standard FMVSS 116 DOT 4 requirements.
x Using another brake fluid, or one that is not of high quality, can impair the function of the brake system and reduce its effectiveness. If the container does not say that the brake fluid complies with VW Standard 501 14, or U.S. Standard FMVSS 116 DOT 4, do not use it.
x The brake fluid must be new.
WARNING
Brake fluid is poisonous.
x To reduce the risk of poisoning, never use food, beverage or other non-original containers to store brake fluid. Someone might be misled by the original label on the container, or by the shape of the container, and drink the brake fluid. This could occur even if you relabel the container as “brake fluid.”
x Only store brake fluid in the closed, original container and keep it out of the reach of chil-dren.
NOTICE
Brake fluid will damage vehicle paint, plastic parts and tires. Wipe any brake fluid off vehicle paint and other vehicle parts immediately.
Brake fluid can pollute the environment. Brake fluid that has leaked out must be collected and disposed of properly, following all applicable environmental regulations.

Adjust the tire pressure
The proper tire pressure helps reduce rolling resistance as well as fuel consumption.
When purchasing new tires, always make sure that the tires are optimized for lower rolling resistance.
Use low viscosity engine oil
Fully “synthetic,” low viscosity engine oils that expressly comply with Volkswagen oil quality standards reduce fuel consumption. Low viscosity engine oils reduce the frictional resistance on the engine and are distributed more evenly and quickly, particularly when cold-starting the engine. The effect is partic-ularly apparent in vehicles that frequently travel short distances.
Always ensure the right engine oil level is maintained and keep to the scheduled service intervals (engine oil changes).
Make sure the engine oil that you purchase expressly complies with Volkswagen oil quality standards and is the oil approved by Volkswagen for your vehicle.
Avoid unnecessary weight
The lighter the vehicle, the more economical and eco-friendly it will be. For example, an extra 220 lbs (100 kg) of weight increases fuel consumption by up to 1 pint per 60 miles (0.3 l/100 km).
Remove all unnecessary items and unnecessary dead weight from the vehicle.
Remove unnecessary aftermarket components
The more aerodynamic the vehicle, the less fuel it will consume. Aftermarket components such as bicycle racks reduce its aerodynamic performance.
Therefore, remove unnecessary structures and unused rack systems, particularly if planning to drive at higher speeds.