Fixing a Siezed Porsche 911 (996) headlight washer pump

Like most headlight washers yours has probably seen little use. The windshield and headlight systems have seperate pumps.

Disuse leads to setting of the seals and siezing. Fortunately this is relatively easy to fix (say 3 out of 10).

The pump and reservoir are located in the drivers side front fender.

Jack up the car, remove the drivers side front wheel.

Lubricate (with WD-40 or similar) all the clips and nuts on the fender well cover fasterners.

Remove all the fender well cover fasteners

Peel and fold the fender cover forwards to expose the reservoir which runs over the top of the wheel almost to the headlight.

Disconnect the front outlet pipe, near the headlight. Remove the front reservoir bracket and bolt.

Disconnect the mid upper outlet pipe near the top of the fender well.

Lower this pipe into a bucket to drain the reservoir!

Open the boot and remove the plastic cover over the windsheild washer filler cap, remove cap first.

Release the catch on top of the filler cap assembly and slide out of the reservoir.

Remove the center reservior bolt.

Pull the reservoir forward out of the rear rubber mountings. This is the hard part as they may be quite stiff

An awl and wd-40 can be used to get lube between the pipe and the pump outlet to easily remove the pipe from the pump

Pry the taller headlight washer pump up and it will pull out of the reservoir (Oh yeah, DRAIN THE RESERVOIR FIRST)

There is a white three pointed star looking macerator at the bottom of the pump inlet. It spins with the pump impeller.

Turn the pump upside down. Spray in a liberal amount of WD40.

With needlenose pliers keep turning the macerator until it moves freely, This may take 20 or more turns.

If you have not unplugged the pump, turn the ignition on and test the pump AFTER draining all the WD40 out.

Reassemble everything and make sure to reconnect the front and rear reservoir outlets.

Sometimes the best advice is given freely,

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