JEGS 90844 Electric Hideaway Headlight Door Upgrade Kit Instructions
- June 13, 2024
- JEGS
Table of Contents
JEGS 90844 Electric Hideaway Headlight Door Upgrade Kit
Disconnect the battery before installing
The installation is done with existing headlight parts in the car. Both
headlight sides are installed in the same manner but the supplied billet
brackets are side-specific and marked “P” for the passenger side and “D” for
the driver’s side. Remove your black plastic grille piece in front of the
vacuum actuator. Each grille piece is mounted with two bolts on top of the
nose section. Remove the vacuum hoses from the vacuum actuators. Make sure you
plug these hoses to prevent poor engine performance from the resulting vacuum
leak.
Remove the following
Vacuum canister, mounted with two nuts on the vacuum canister bracket.
- C-clip
- Large coil spring
- Small flat steel bracket on door crank attached with one sheet metal bolt (aka over-center bracket)
- A small square plastic bushing
The original black “clam-shell” plastic bushing holding the door crank (see
photo below) is often missing, partially broken, or about to disintegrate. We
have included this easily installed bushing along with other
door bushings that may have deteriorated over the years. In most cases, only
the clam-shell bushing needs to be replaced. Install the movable (top)
actuator bracket (driver or passenger-side specific) using the supplied 10/24
lock nut and flat-head screw. The bracket should fit perfectly in the square
hole of the headlight door crank but may need to be squeezed in place with a
pair of pliers. The fixed (lower) actuator bracket mounts to the original
vacuum canister bracket using the two original vacuum canister mounting holes
and supplied ¼” Allen bolts. Mount the rear bracket with the actuator fork
facing outward.
Mount the electric actuator to the actuator brackets using the supplied stainless shoulder bolts. The actuator is supplied in the half-open position. A little grease on the shoulder bolt is recommended. Fine-tune the actuator length to fit the actuator brackets by unscrewing the door actuator ram. The actuator ram should be screwed out less than 8 full turns from screwed all in. Additional door adjustment can be obtained by adjusting the two original bolts holding the door crank to the door assembly.
Connect the actuator plug to the control box plug. The control box should be installed in an area protected from high-pressure water spray and must be installed with the mounting ears facing down. A good spot to mount the control box is the bottom lip of the Endura bumper right below the removed grille piece. The control box can be mounted using screws, industrial Velcro, 3M Car Accessory tape, silicone glue or epoxy.
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WARNING! The battery MUST be disconnected before installing control boxes
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WARNING!: Wires MUST be installed in the following order or damage may occur
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Black wire – Is ground. Connect to any ground source (i.e. headlamp housing or radiator support).
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Red wire – This is the power supply to the motor and must be connected to a permanent non-switched (always on) power source such as directly to the positive side of the battery. Each control box needs
a 4 amp fuse, which is supplied in the kit. -
Yellow wire – Must be spliced to any low-beam wire. In most cases, the best splice point is right behind the plug connected to the three-prong headlight bulb. Blue splice connectors are included in the kit for this.
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White wire – Must be spliced to any high beam wire. In most cases, the best splice point is right behind the plug connected to the three-prong headlight bulb. Blue splice connectors are included in the kit for this.
Re-connect the battery, install the headlamp assembly, and enjoy your hideaway headlights. Final fine-tuning of the door movement is completed by turning the actuator ram in or out. Sometimes it is easiest to make the final adjustments with the actuator ram partially open or partially closed by disconnecting the grey plug to the actuator while the actuator is in motion.
Notes
Once the headlight doors are in motion, the headlight switch should not be
operated until the headlight has fully extended. The headlight door closing is
delayed a couple of seconds to allow the flashing of the headlights (to alert
oncoming traffic) without the headlight doors shuddering. To leave the
headlight doors in the open position (i.e. for cleaning or lamp change) turn
the headlights on and disconnect the grey plug between the actuator and the
control box, then turn the headlight switch off
Read User Manual Online (PDF format)
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