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Old 02-22-2015, 10:45 PM   #1
zeal86
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DIY: Smaller Windshield Washer Reservoir

First off... shout out to @Whatabouteggs for finding and posting this link ACI 99300 Windshield Washer Pump

The factory reservoir is effing huge and takes up too much real estate. As a provision for when I go forced induction I wanted to complete this modification... especially while I have my front bumper off.

I purchased the aforementioned windshield washer reservoir with the idea that I could make it work in my 86. After brainstorming some ideas I came up with the following:


覧覧覧覧覧覧覧覧覧


This coupler I acquired from a mini attachment for vacuums bundle from Harbor Freight - $5.99-$8.99. I believe it is 1 1/4" on one side 1 1/8" on the other.



When pressed into the factory fill neck... a lip is present. I used a 45 degree test probe to score the pattern I would Dremel later.

**Fitment here is tight... does not require a clamp.**



Scored pattern to Dremel.



Knotched out.



Flush with factory fill neck.



I purchased the flexible hose (1 1/4" bilge and pump) from Ace Hardware for $3 and some change...You'll find it in plumbing. I used a little over a foot.

**Clamp is required here for secure fit.**



I found this in the lumber section of Home Depot. The part is called a twisted strap. The part number is LTS12 and the barcode is 44315 93300.

**I had to cut a portion out with tin snips so I could bend the bracket a bit. I also cut a section off the top because the twist strap was too tall. **



Bend bracket over the resevoir as pictured.



Prepped for paint.

**I lined up and drilled hole that secures bracket to chassis prior to paint. I used factory reservoir bolt to secure to chassis. This installs in the upper factory reservoir nut plate.**



Painted and clear coated to protect against corrosion.



I secured the twisted strap bracket to reservoir under the bracing and with a strip of all weather 3M double sided tape.

**Previously prepped and painted reservoir bracing.**





I purchased this part at Ace Hardware for like $4 and some change.

**Comes with clamp...not pictured**



I used flexible hose end to stencil area to cut.



Installed with provided clamp.



Spacers, bolt, and a nut required here. I used a 1 inch spacer and a 1/2 inch spacer I had. I used a 10mm bolt and nut I had to secure bracket to chassis.

**Spacers create the necessary area required to clear wheel well liner.**



Close up pic.



Mounting completed.



I modded the factory plug/connector instead of tapping into factory wires. Yellow wire is positive on factory end... so connect with red wire from reservoir motor.

I unclipped connector from factory reservoir using small flat tip screw driver. I chose to remove the seal and replace with 3M strip caulk.



I used a hole saw (1 1/2 - 38mm) to cut through an ABS plastic scrap I had.

**Dremel away the rough edges.**



I lined up the pins and drilled a hole big enough to accommodate pins and soldered/heat shrunk wires from new reservoir motor.



I used JB Weld for Plastics to seal center hole created by hole saw.



I placed some 3M strip caulk to act as a seal and adhesive.









Although the strip caulk holds tight I wrapped a zip tie around the plug/connector just in case.






Plugged in and secured with zip ties.





Last edited by zeal86; 08-04-2015 at 07:07 PM.
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Old 03-21-2015, 08:46 PM   #2
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Because of the installation of my Beatrush front beam brace, I had to make an adjustment to my windshield washer reservoir mod... adjustment would have probably been necessary even with the OEM beam brace though.







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Old 03-21-2015, 11:58 PM   #3
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Removal of the OEM version

How did you remove the OEM version. The instructions here seem to miss some undocumented clips or screws.


http://intranet.toyotaperu.com.pe/td...034yk03fx.html
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Old 03-22-2015, 12:40 AM   #4
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Originally Posted by Iwannajag View Post
How did you remove the OEM version. The instructions here seem to miss some undocumented clips or screws.


http://intranet.toyotaperu.com.pe/td...034yk03fx.html
Well, I removed my OEM windshield washer reservoir from the front since I currently have my front bumper off. I did not remove it as illustrated in your link so I don't have an answer to your question.

There were two bolts from what I remember... I'm not sure if the top bolt would be easily accessible from the wheel well. To pull off this mod (if that is your intention) I would advise that you remove the front bumper.

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Old 05-08-2017, 11:52 AM   #5
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This is exactly what I need to make room for brake ducting on my track build. Great DIY!!!
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Old 05-15-2017, 04:53 PM   #6
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Installed my brake ducting this weekend, and this washer bottle to make room for it. Couple of observations - the factory pump provides a much stronger stream, and the included bracket for the tank is super flimsy.

Just be aware if you go this route
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Old 05-15-2017, 05:13 PM   #7
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Originally Posted by Joesurf79 View Post
Installed my brake ducting this weekend, and this washer bottle to make room for it. Couple of observations - the factory pump provides a much stronger stream, and the included bracket for the tank is super flimsy.

Just be aware if you go this route
I've actually never used the washer fluid from either the OEM or aftermarket bottle...

Thanks for providing the input for others..I made my own bracket that passed through the provided bracket. My install did not feel flimsy though.

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Old 05-15-2017, 08:04 PM   #8
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This seems to be much cheaper vs the OEM Toyota Motorsport version but you gotta hack it up with this DIY.
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Old 05-15-2017, 08:20 PM   #9
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This seems to be much cheaper vs the OEM Toyota Motorsport version but you gotta hack it up with this DIY.
I don't think there is too much hacking involved in pulling this mod off. I used the OEM plug but I didnt have to... I could have spliced and soldered my connections.

If I were to redo this mod I would use sheet metal, a press shear, and a metal break to make my bracket.

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Old 05-15-2017, 08:23 PM   #10
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Originally Posted by zeal86 View Post
I've actually never used the washer fluid from either the OEM or aftermarket bottle...

Thanks for providing the input for others..I made my own bracket that passed through the provided bracket. My install did not feel flimsy though.

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Never? I can't even imagine what that is like. Driving year round in Canada I would strap a 45 gallon drum of stuff under there if I could!
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Old 05-15-2017, 08:40 PM   #11
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Never? I can't even imagine what that is like. Driving year round in Canada I would strap a 45 gallon drum of stuff under there if I could!
My 86 is not a daily and it never sees rain. Crazy low miles. Trailered to shows... only driven on really nice days usually on weekends. Plus, I'm always doing something to it....😀

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Old 05-15-2017, 08:46 PM   #12
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My 86 is not a daily and it never sees rain. Crazy low miles. Trailered to shows... only driven on really nice days usually on weekends. Plus, I'm always doing something to it....😀

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Polar opposites.

I knew yours was more a show car but to never have used it boggles my mind. I use a gallon a week for about 4 months of the year.
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Old 05-15-2017, 10:47 PM   #13
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Never? I can't even imagine what that is like. Driving year round in Canada I would strap a 45 gallon drum of stuff under there if I could!
Add me to the list of folks that have never used the windshield washer fluid in the four years I've owned the car. It's my daily driver, but I'm in socal and keep it clean. I clean my windows weekly, so dirt never gets a chance to build up on them.
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Old 05-15-2017, 11:39 PM   #14
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I've never used it either...for all I know it doesn't even work, lol. Same for the seat warmers and probably a half dozen other things.
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