Headlights
Headlight Washer Servicing
Finally decided to install the new clutch this weekend. Had the car jacked up and then the front bumper started to leak some blue fluid. Finally pushed some plastic out of the way and found a spring, plunger and hard plastic cap. It appears to be from the check valve located behind the bumper cover. I tried to push the assembly back together but no luck. Can't seen to get enough pressure with my hands. The location is very confined. Getting any tools in their would be a trick.
Is their any way to fix this or is a new one in order? I like the neat red water fountain display on the dash( low washer fluid), but it is getting old after only a day. In any event can someone tell me how to get the old one out without removing most of the bumper. Nasty location.
John Veninger
1990 928GT
Just remove the headlight on the side that you need access to. Don't mess with bumper cover or you'll likely crack or scratch your paint. You could also break on of those tiny little bolts that hold the bumper cover on and then you'll be sorry.
Here's my take:
1. Remove inner fender cover (in front of front wheel).
2. Turn on and raise headlights.
3. Break battery ground at dreaded wingnut leaving headlights up.
4. Remove headlight assembly cover.
5. Remove lamp assembly.
6. Loosen wiring from bottom of headlight shroud (two clips with phillips head screws).
7. Remove clamp bolts at inboard of fender in engine compartment.
8. Remove headlamp assembly bearing bolts and nut plate (long wobbly extendsion on 1/4" drive).
9. Remove lamp base assembly.
10. R&R check valve.
2 hour job, tops!
jay k.
>My question is regarding the headlight washers. The main line that comes
>out of the reservoir and goes around the passenger side corner to where ever
>has become disconnected.
I just got done with this fix last week! Only my hose was attached. My check valve under the bumper cracked and leaked all of the fluid from the reservoir. The main fluid line from the reservoir runs past the passengers headlight to a check valve behind the bumper. From this check valve two hoses run to the headlight washers. You can gain access by holding the top section of the top plastic out of the way on the bumper through the radiator vent. This would be the second section from the passenger side. This is a little harder to explain than do. Especially without pictures. At this point you can touch the check valve, but that's it! You should re-feed your disconnected reservoir line back under the bumper and through this bumper opening.
You need to jack up the passenger side and remove the front wheel. Now remove the wheel liner and the front liner exposing the headlight assembly. Raise the headlights manually or with the switch. Locate the reservoir hose running along the top of the fender. Unclip it from the fender and cut it near the shock tower. Now reach in by the headlight and remove the hose from the passenger headlight washer. Take the end of the hose from the washer and tape or zip tie it the main fluid feed line located right next to it. Now reach back under the bumper and pull the check valve through the opening. You will need to feed the reservoir line as it bends around the corner. Now you will have enough slack to pull the check valve out to replace it.
After replacing make sure to use new hose clamps on the check valve. Pull the main reservior line back into the passenger wheel well and reconnect the headlight washer line. Now use a plastic or brass barbed hose splice w/ two hose clamps to splice the main fluid line back together. I wrapped mine with some electrical tape to prevent any type of rattle. Replace all the liners, replace the wheel and fill the reservoir with fluid.
John Veninger
1990 928GT
928OC