Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSVOLKSWAGEN2002PASSAT GLX 4MOTION, 4D SEDANREPAIR AND DIAGNOSISBODY & FRAMEWINDOWSBODY EXTERIOR64 GLASSFLUSH-BONDED WINDOWSINSTALLATION NOTES

2002 Volkswagen Passat GLX 4Motion, 4D Sedan

Installation notes

2002 Volkswagen Passat GLX 4Motion, 4D SedanSECTION Installation notes

Fig 1: Applying Adhesive Material All Around Onto Pre-Coating -1-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply adhesive material all around onto pre-coating - 1 - at right angle to window.

CAUTION: Window must be installed within 10 minutes, otherwise bonding properties of window adhesive will be impaired.

Insert window into window cut out using two Double suction lifters V.A.G 1344, center and press in up to spacer.
Gap dimension of windshield: → Windshield, assembly overview
Rear window gap dimension: → Rear window, assembly overview
Gap dimension of rear window, wagon, 4.5 mm all around.

Secure windshield using Window adjuster 443 845 631 A during curing time.
Plenum chamber cover must always be installed as described: → Plenum chamber cover, removing and installing .
Re-affix any stickers (e.g. for airbag).

Fig 2: Installing Rear View Mirror

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing mirror - 1 - , attach at 6090° offset to installation position and turn - arrow - until retaining spring engages.
Install interior mirror: → 68 - INTERIOR EQUIPMENT
Install interior mirror with rain sensor: → 92 - WINDSHIELD WIPER AND WASHER SYSTEM

Secure rear window using adhesive tape during curing time.
If adhesive bead has been applied too thick and adhesive expands onto area of window heating, then excess adhesive must be removed.
First install side window of wagon using securing pins.
When re-using removed window:

Fig 3: Insert Window Into Body Flange And Align To C-Pillar -A- And D-Pillar -B-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert window into body flange and align to C-pillar - arrow A - and D-pillar - arrows B -.

Secure side window using adhesive tape during curing time.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.