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:


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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.

http://i41.photobucket.com/albums/e2...1131142308.jpg

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.**

http://i41.photobucket.com/albums/e2...1131638256.jpg

Scored pattern to Dremel.

http://i41.photobucket.com/albums/e2...1132021254.jpg

Knotched out.

http://i41.photobucket.com/albums/e2...1133315855.jpg

Flush with factory fill neck.

http://i41.photobucket.com/albums/e2...1133553511.jpg

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.**

http://i41.photobucket.com/albums/e2...1140254714.jpg

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. **

http://i41.photobucket.com/albums/e2...1141659222.jpg

Bend bracket over the resevoir as pictured.

http://i41.photobucket.com/albums/e2...1143814998.jpg

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.**

http://i41.photobucket.com/albums/e2...1151023199.jpg

Painted and clear coated to protect against corrosion.

http://i41.photobucket.com/albums/e2...1223640043.jpg

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.**

http://i41.photobucket.com/albums/e2...1225427309.jpg

http://i41.photobucket.com/albums/e2...1225624345.jpg

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

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

http://i41.photobucket.com/albums/e2...4661687179.jpg

I used flexible hose end to stencil area to cut.

http://i41.photobucket.com/albums/e2...2143950737.jpg

Installed with provided clamp.

http://i41.photobucket.com/albums/e2...2150325373.jpg

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.**

http://i41.photobucket.com/albums/e2...2150426196.jpg

Close up pic.

http://i41.photobucket.com/albums/e2...2-18-51-12.png

Mounting completed.

http://i41.photobucket.com/albums/e2...servoir%20.jpg

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.

http://i41.photobucket.com/albums/e2...1182721611.jpg

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

**Dremel away the rough edges.**

http://i41.photobucket.com/albums/e2...1184224877.jpg

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

http://i41.photobucket.com/albums/e2...1190021909.jpg

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

http://i41.photobucket.com/albums/e2...1192728285.jpg

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

http://i41.photobucket.com/albums/e2...2182749744.jpg

http://i41.photobucket.com/albums/e2...r%20Plug04.jpg

http://i41.photobucket.com/albums/e2...r%20Plug03.jpg

http://i41.photobucket.com/albums/e2...r%20Plug02.jpg

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

http://i41.photobucket.com/albums/e2...r%20Plug01.jpg


http://i41.photobucket.com/albums/e2...her%20Plug.jpg

Plugged in and secured with zip ties.
http://i41.photobucket.com/albums/e2...rvoir%2003.jpg

http://i41.photobucket.com/albums/e2...rvoir%2002.jpg

http://i41.photobucket.com/albums/e2...ont%20View.jpg

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.

http://i41.photobucket.com/albums/e2...round%2002.jpg

http://i41.photobucket.com/albums/e2...round%2001.jpg

http://i41.photobucket.com/albums/e2...karound%20.jpg

projekt zeal86 build

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

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.

projekt zeal86 build

This is exactly what I need to make room for brake ducting on my track build. Great DIY!!!

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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projekt zeal86 build

zeal.eightsix Facebook

Instagram @zeal.eightsix

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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projekt zeal86 build

zeal.eightsix Facebook

Instagram @zeal.eightsix

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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projekt zeal86 build

zeal.eightsix Facebook

Instagram @zeal.eightsix

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.

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.

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.