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Windshield Washer Reservoir Replacement
 
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Pelican Technical Article:

Windshield Washer Reservoir Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$140

Talent:

**

Tools:

10mm socket, Philips and flathead screwdriver, pliers, floor jack, jack stands, wheel chocks, safety glasses

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Reservoir

Hot Tip:

Use care, as the plastic gets brittle

Performance Gain:

Working washers

Complementary Modification:

Radiator flush

Over time, the windshield washer reservoir tends to crack, break and leak. If you are starting to see a small pool of fluid under the right front corner of your Porsche 944 or 951, there is a good chance your reservoir is going bad.

The reservoir is located in the front right corner of the engine compartment. The pumps sit in/on the actual reservoir itself. The reservoir is not an easy quick fix, as several components that need to be moved to get it in and out of the vehicle. If you take your time and remove what needs to be removed, you should be able to complete the job in less than two hours. Do not try forcing the tank out, as you will just break it. Take your time and remove what is necessary. Even with everything out of the way, the tank is a tight fit going in and coming out.

Begin by suctioning out as much of the fluid as possible. You want to get as much fluid out as possible. Once you remove the headlight pump any remaining fluid in the reservoir will flow out through the pump grommet in the bottom of the reservoir.

You will need to have the headlights in the raised position to remove the reservoir. Please see our article on headlight motor replacement for further assistance.

The reservoir comes out from the bottom of the vehicle, so safely raise and support it. Please see our article on safely raising and supporting your Porsche 944 and 951.

The reservoir is located in the right front corner of the engine compartment (red arrow).
Figure 1

The reservoir is located in the right front corner of the engine compartment (red arrow).

You will need to have the headlights in the up position.
Figure 2

You will need to have the headlights in the up position. Remove the cover from the motor and manually raise the lights (red arrow). It is also a good idea to disconnect the wiring for the motor to give you more room to work.

The windshield pump (red arrow) is mounted on the top front of the reservoir and pulls the coolant from the cap (green arrow).
Figure 3

The windshield pump (red arrow) is mounted on the top front of the reservoir and pulls the coolant from the cap (green arrow). The cap was missing on our project car. If it is missing on yours you should replace it right away. The cap seals the reservoir, which prevents dirt and debris from getting in, while also stopping the fluid from spilling out. From the pump there is a line that runs up to the windshield nozzles (yellow arrow). Pump out as much fluid as you can or be prepared to catch the fluid from the bottom when you remove the headlight pump.

Remove the fluid lines from the pump (yellow arrow), using care, as the plastic nipples on the pump get very brittle over time and can break off in the lines (red arrow).
Figure 4

Remove the fluid lines from the pump (yellow arrow), using care, as the plastic nipples on the pump get very brittle over time and can break off in the lines (red arrow).

Disconnect the electrical connection (red arrow).
Figure 5

Disconnect the electrical connection (red arrow).

There is a plastic clip (red arrow) that helps hold the pump in place on the bracket and reservoir.
Figure 6

There is a plastic clip (red arrow) that helps hold the pump in place on the bracket and reservoir.

Slide the clip and piece between the clip and mount (red arrow) towards the center of the car.
Figure 7

Slide the clip and piece between the clip and mount (red arrow) towards the center of the car. This will allow you to slide the pump over until the plastic tabs on the reservoir can slip out from the holes in the mounting plate (yellow arrow).

With the clip slid over you can remove the pump from the mounting tabs on the reservoir (red arrows).
Figure 8

With the clip slid over you can remove the pump from the mounting tabs on the reservoir (red arrows). Installation is the reverse of removal.

Next, remove the headlight pump (red arrow) from the lower section of the reservoir by pulling it up and out from the grommet it sits in.
Figure 9

Next, remove the headlight pump (red arrow) from the lower section of the reservoir by pulling it up and out from the grommet it sits in. Please see our article on headlight pump replacement for further assistance.

There will be a single large Philips head screw or 10mm bolt connecting the reservoir to the front fender area.
Figure 10

There will be a single large Philips head screw or 10mm bolt connecting the reservoir to the front fender area. Remove this Phillips head fastener.

The reservoir sits behind the front wheel well liner (red arrow).
Figure 11

The reservoir sits behind the front wheel well liner (red arrow). You will need to remove the liner. Please see our article on wheel well liner removal for additional assistance.

Remove the two 10mm bolts that hold the air duct to the front brake (red arrows), and then remove the duct.
Figure 12

Remove the two 10mm bolts that hold the air duct to the front brake (red arrows), and then remove the duct.

There are is a 10mm nut that holds the reservoir to the rail close to the engine; pull the wire clip off and remove the nut (red arrow).
Figure 13

There are is a 10mm nut that holds the reservoir to the rail close to the engine; pull the wire clip off and remove the nut (red arrow). The bolt that the nut sits on is stuck between the mount and the rail, so you will need to bend the reservoir over it. Next, remove the 10mm bolt holding the reservoir to the air duct bracket (yellow arrow).

There are still two things blocking pulling the reservoir out from the bottom.
Figure 14

There are still two things blocking pulling the reservoir out from the bottom. You will need to move the oil cooler (yellow arrow). You do not need to disconnect it. Just remove the two 10mm bolts and rubber isolators (red arrows) and let it hang by the lines out of the way. The power steering lines (green arrow) can stay mounted, but you will need to gently pull them towards the front of the car to clear the reservoir as you lower it.

It is a tight fit, but you can now lower the reservoir out from the mounting area (red arrow).
Figure 15

It is a tight fit, but you can now lower the reservoir out from the mounting area (red arrow).

With the reservoir out you can see where it mounts to the chassis (red arrows) and where the windshield pump (green arrow) and headlight pump (yellow arrow) go.
Figure 16

With the reservoir out you can see where it mounts to the chassis (red arrows) and where the windshield pump (green arrow) and headlight pump (yellow arrow) go. Installation is the reverse of removal. It is a tight fit getting it back in. Do NOT force it. You run the risk of damaging your brand new reservoir.







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