Please note If you have one of the newer 2ndgens and don't have the bed storage pockets that would allow you to gain access behind the gas door you can go from under the fender liner. In which case this its not quite the easy bolt on project. Some members have done it but it does add some difficulty so just a heads up if your reading this to see whats involved.
- Install and wire up your momentary button. Since everyone will have their own preference on what button they want and where to put it I will leave that part up to you. Basically one wire of the actuator goes to ground and the other wire will go through your momentary button to a constant 12+ or to ignition controlled 12+. Again, its whatever you prefer. I started with the standard issue radio shack button and ended up using a VW button I got from ebay for about $14. It's an illuminated button but I didn't feel like wiring that part up.There are random rubber plugs under the seats in the cab that you can cut a small slit into and use to run the wires outside the cab and to the bed of the truck.
- Remove the bed storage pocket and reach in and pinch together the top/bottom barb like prongs and wiggle out the post toward the gas cap. I was able to do both of these steps while standing on the outside of the truck and just reaching over the bed rail.
- Next, pull your wires from the dash button through the pocket and connect them to the actuator. You can use female bullet connectors to match the male plugs on the unit or cut them off and use crimp caps, solder/ heat-shrink or whatever you like. The blue wire on actuator gets connected to ground and the green goes to 12+ through your momentary button.
- Remove the 14mm nut off the unit and feed the threaded end of unit through the empty square hole left by the removed post. I might be a tight fit and but it should go through. You might have to give it some sweet talk or lightly file the hole just a bit. Unscrew the factory door clip and replace with the machined latch. The slot on the latch for the screw allows you to adjust it fore and aft so you can get it as close to the nut without hitting it while the door swings open/close.
- You may or may not need to get a spring for your install. I've installed and uninstalled a number of times for testing and each install seems to vary just a little bit. Once I was able to get some spring action off the rubber bumpers alone. Another time the door had no spring at all so it just sat still when unlocked and would just relock itself after I hit the button. I found one at my local ACE Hardware to help kick the door open when unlocked. I slightly closed up one of the coils so it would push onto one of the bumpers without falling off. I tried a variety of spring types and got most of em to work such as foam weather strip or metal strapping band. The Ace one I ended up with is .500 diameter x .530ish in length with .040 coils if that helps. I also stuck a piece of electrical tape on the door to protect the paint.
That should be it.