Windshield washer system fix

[Jedman]

Guys,

If any of you have a slow or non-working windshield washer line, this post may help.  I just finished working on a clogged system on my own Zukie with Joe S.  Here is what we did:

First, I removed the washer fluid reservoir, emptied it out and completely scrubbed it clean.  I also took off the small electric pump and cleaned all the gunk off it.  There was a LOT of sediment in the reservoir.

Next, we took the windshield down.  This is a fairly simple process and only required removing 12 bolts.  They are located as follows on each side:  two that hold the door frame to the targa bar, one that holds the safety bar to the targa, two that hold the inside of the windshield to the firewall, and one that holds the outside of the windshield to the front hood area.  We chose to keep the door frame and safety bars attached at the windshield and remove them from the targa bar because it allowed us to keep the rubber weather strip intact along the door frame.  Don't forget to remove the little plastic protectors on the outside of the windshield.  These, I found out, are held on with double stick tape so you'll need to clean off the old tape and put on new when you reassemble.

Once these bolts are out you will need to prop up the windshield.  We couldn't lay it down on the hood because the antennae wire was too tight.  However, you could probably disconnect it from your radio and the windshield would then lay flat on your hood.

Now you will be able to reach the washer fluid hose that goes into the center spray valve.  You should find a small blue valve about six inches from the windshield.  This is probably the culprit.  On my Sammie, it was completely clogged with sediment.  All you need to do is remove this blow though the ball bearing valve end.  I don't know how else to describe this.  I also blew some parts cleaner into it from the ball bearing valve side as well.  This cleaned out all the gunk.

Before reassembling, we ran the washer fluid motor to make sure it was coming out easily.  It was.  Reconnect the blue valve, making sure the ball bearing side is toward the reservoir part of the hose.  If you put this valve in backwards it will not allow the washer fluid to pass through the hose.

Put your windshield back on and you're golden.

Joe, if I left anything out or was not accurate in my write up, please add your comments and corrections.

I forgot to take pictures.  I wish I had because that would make my descriptions more clear.

[Jedman]

Forgot something... 

When you are removing the bolts, you may need to use an impact driver to free them.  Someone else on these board suggesting a small butane torch you can pick up from HFT.  However, since Joe had an impact driver that is what we used.  All the bolts came out with no problems.

[catfishblues]

Forgot something... 

When you are removing the bolts, you may need to use an impact driver to free them.  Someone else on these board suggesting a small butane torch you can pick up from HFT.  However, since Joe had an impact driver that is what we used.  All the bolts came out with no problems.

Thanks for the endorsement!  I probably would have tried the impact driver except for the fact that my #3 bit was broken due to using it on more stubborn bolts. I've had mixed success using the impact driver, but with the torch I was able to remove all of them using a regular #3 screwdriver. I reinstalled them using my cordless 18v drill with the clutch set to the 2nd from highest setting. Saves a LOT of wrist and hand strain! I had a red spot on my hand for days after this job. 

[Sarge]

All those screws are Pozidrive , if you can find either screwdrivers or insert bits in #'s 1,2 and 3 Pozi it sure helps . I have a complete set of hand drivers as well as bits and use 'em a lot . Check around for a Wiha dealer , they make some very high quality ones....
Sarge

[Joe S.]

great write up frank! it was nice meeting you. i'll try to remember my digicam next time we start a project.

I've had mixed success using the impact driver

on some samis i have disassembled, i actually have bent sheet metal with the impact.  frank's sami was so clean, i didnt figure we would have any problems with screws being that stubborn. luckily, i was right.

[libeachbum]

What does the valve do? i just ran the hose straight from the resevoir into the washer nozzle and no problems with that, but doesn't shoot high enough onto the windshield.

[catfishblues]

All those screws are Pozidrive , if you can find either screwdrivers or insert bits in #'s 1,2 and 3 Pozi it sure helps . I have a complete set of hand drivers as well as bits and use 'em a lot . Check around for a Wiha dealer , they make some very high quality ones....
Sarge

You mean the Phillips with the extra tangs in between the slots? Just having a good, sharp screwdriver to start with makes a big difference. Most folks don't realize how easy it is to ruin a phillips bit, and then they start rounding screws. The driver I use will hang horizontally in a good screw. I like heat because it breaks down the loctite they use at the factory, and I don't have to bring out the air impact or hammer impact. Those are my last resort, as I have ruined more screws than I have removed with them.

[Bearsden]

A good chisel and hammer works so good and not hard on screw drivers
When all them phillips head screws are out, throw them as far as your arm
will let you,, then install stainless steel bolts,, you'll never have trouble taking
them off with a socket and ratchet 

[Trimixer]

What does the valve do? i just ran the hose straight from the resevoir into the washer nozzle and no problems with that, but doesn't shoot high enough onto the windshield.

Its probably a non return valve so the water doesn't drain all the way back to the reservoir and cause a delay each time you switch it on.  Seems unnecessary. Mine doesn't have one and t sprays instantaneously.   

[Surly]

...but [the water] doesn't shoot high enough onto the windshield.

You can aim the squirter nozzles to shoot water wherever you want... just stick a pin into the opening(s) and use it to move the nozzles around. They swivel! HTH

[libeachbum]

You can aim the squirter nozzles to shoot water wherever you want... just stick a pin into the opening(s) and use it to move the nozzles around. They swivel! HTH

Wow, didn't know that, thanks.