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For those wanting to add hoodlifts...
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All right, here it is, FINALLY! For those of you wanting to DIY hoodlifts on your B4 (or B3, possibly), here are the instructions I used to install both mine today, took about 30 minutes and simple hand tools.
DISCLAIMER: I assume no responsibility for damage you may incur as a result of performing this procedure from these directions. If you are not mechanically inclined DO NOT attempt this procedure.
Okay, now that that's out of the way, here goes. I used the following simple hand tools to install the lifts:
-10mm 1/4 inch drive deep well socket (to remove two bolts on top of the fender)
-11mm 1/4 inch drive deep well socket (to install the 4 mounting studs for the lifts)
-1/4 inch drive ratchet
-vice grip pliers (to remove the bolts in the hood since I didn't have the PROPER star tool)
-Cordless drill (Makita) with a small unibit (to enlarge the mounting holes on top of the fenders so the studs will thread into them).
I installed two lifts, I suggest you do the same as the Passat hood is heavy and I personally feel safer with both of them installed.
Here's what the install went on:
First, open the hood and prop it with the installed prop rod (which you can later get rid of, AFTER you install the lift(s)
Here are the lifts, Mighty Lift, part number E95212, 16.99 from Auto Zone:
The bolt with the grounding strap attached is the bolt you will remove with the vice grip pliers (or star shaped tool). You do NOT need to install the included washer from the hoodlift as the grounding strap takes the space of the washer. The same bolt (more forward on the passenger's side) will be removed when the passenger side is done.
Driver's side
Passenger's side (install the washer since no strap is here)
Driver's side (with bolt removed)
Note: Passenger's side will look the same (forward bolt removed)
Now, open one hood strut package and remove the mounting hardware. Upon breaking open the plastic remove one mounting stud and screw it into the hole where the hood bolt was removed. Install the grounding strap over the bolt, and use the 11mm deep well socket and 1/4 inch ratchet to tighten the bolt. Snug this bolt down good but do not overtighten as you will strip the bolt and then you're screwed! When it is installed on one side (driver's or passenger's), move to the other side and repeat. You now have two mounting studs (both installed in the hood hinge).
Now it's time to move to the fender strips. This is the tricky part and if you mess it up (get the hole too big for the stud) the install cannot be completed (as you can't make the hold smaller very easily).
On each fender strip you will see three screws. I have pointed to each screw (in both cases, the middle screw) that needs to be removed in order to bore out the hold for the mounting stud:
Driver's side:
Passenger's side:
Using the 10mm deep well socket and 1/4 inch ratchet, remove both screws (you should now have a total of 4 leftover parts, whoever said you couldn't reduce weight on a VW and still have performance...)
NOTE: I cannot stress enough the importance of taking your time in this portion of the procedure. You've heard the phrase "measure twice, cut once'? Well, this couldn't be more applicable than here. This is the most delicate part of the whole procedure. Messing this up will ruin the install and, quite frankly, your day as well, so be VERY CAREFUL when you do these next steps. It is better to drill a little at a time and test fit the stud than to bore out the hole TOO big.
VERY CAREFULLY insert the small unibit (attached to the cordless drill) and bore the hole out until the threads of the bolt sit on top of the hold in the fender strip (the one the bolt came out of). It will seem too small to fit but that's the only way the stud will thread into the sheetmetal. I took the vice grip pliers and vertically attached them to the end of the stud so I could apply downward pressure on the stud
as I slowly turned it in an attempt to get it to thread. You want to make sure you are also starting the stud at a level plane as angling it will only throw off the mounting. Once the stud is threaded (you'll feel it get difficult to turn), take the 11mm deep well socket and 1/4 inch ratchet and SLOWLY turn the stud (no washer) until it is fully turned into the fender strip (it will get tight, but don't overtighten, again, or it will strip out, and then just flop around).
Installed stud on driver's side (passenger's side is same):
Finally, it's time to install the struts. The black strut cartridge goes down, with the shiny piston going up (see pics). On the passenger's side (recommend doing it first since the prop rod is holding up the driver's side), pop the strut onto the hood stud, and, with your right hand, push the hood back toward the windshield enough to get the strut to pop onto the fender strip stud. When both are popped on (you can pull on them, they won't come off if you installed them correctly, and you can feel them pop into place), raise hood and remove prop rod (letting it rest in it's natural position), and repeat process on driver's side but reverse hands (left hand on hood, right hand on strut). Here's installed pics of both sides:
Driver's side: (note grounding strap installed)
Passenger's side:
When both are installed, step back and enjoy the fruits of your labor:
A side note: As these are NOT perfect fits, your hood will bulge up a little (you will have to work with the bolt placement on the hood to get the hood to lay down a little better) OR you can just live with it. Either way, I hope you enjoy this DIY. Let me know if I can improve on it or if you like it, all comments welcome, good or bad...
Mike
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Click on the thumbnails to see larger images.
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