Washer Reservoir

This procedure covers removal and replacement of the windshield washer reservoir on a 1966 Chevrolet Corvette with 327ci V8 engine.

Warnings

Tools required

Parts

• Windshield washer reservoir × 1 — Use OEM specification
• Washer fluid hose (if damaged) × 1 — 3/16 inch ID rubber hose
• Hose clamps (if needed) × 2 — 5/16 inch worm gear clamps

Fluids

• Windshield Washer Fluid — 3.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently driven
3. Gather all tools and replacement parts
4. Place drain pan or bucket beneath work area to catch washer fluid

Procedure

1. 1

   Access the washer reservoir
   Open the hood and locate the windshield washer reservoir. On the 1966 Corvette, the washer reservoir is mounted in the engine compartment near the inner fender (verify exact location against factory assembly manual). Use a flashlight to identify the washer jar (often glass on early units) and its mounting strap or bracket.
2. 2

   Disconnect the washer pump electrical connection
   Verify the washer system type on this vehicle. If equipped with an electric pump, locate the electrical connector on the pump. Note: many 1966 Corvettes used a vacuum or mechanically actuated washer system rather than an electric pump. Grasp the connector body (not the wires) and pull firmly to disconnect. If corroded, gently wiggle while pulling to separate.
3. 3

   Disconnect the washer fluid hose
   Using pliers, squeeze and slide the hose clamp away from the pump outlet on the reservoir. Pull the rubber hose straight off the pump fitting. Direct the hose end into your drain pan to catch any remaining fluid.
4. 4

   Drain the reservoir
   Tip the reservoir forward if possible to drain remaining washer fluid into the drain pan. The reservoir should be empty or nearly empty before removal to reduce weight and spillage.
5. 5

   Remove reservoir mounting hardware
   Locate the mounting bracket securing the reservoir to the inner fender. Identify the mounting method (commonly a single metal retaining strap on early Corvette washer jars) and remove the strap fastener(s). Verify the exact configuration against the factory assembly manual before removal.
6. 6

   Remove the reservoir assembly
   Lift the reservoir up and out of the mounting bracket. Maneuver it carefully past any surrounding wiring or components. The pump motor remains attached to the reservoir bottom.
7. 7

   Inspect and prepare new reservoir
   If replacing the reservoir, remove the washer pump motor from the old reservoir by twisting counterclockwise and pulling out. Check the rubber grommet seal on the pump for damage. Install the pump into the new reservoir by pushing firmly and twisting clockwise until seated. Verify the pump is secure and the grommet seals properly.
8. 8

   Position the new reservoir
   Maneuver the reservoir assembly into position in the inner fender well area. Align the mounting bracket holes with the fender mounting points. Ensure the pump outlet faces the correct direction for hose routing.
9. 9

   Install mounting hardware
   Secure the reservoir mounting bracket to the inner fender using the 2 sheet metal screws. Tighten firmly but do not overtighten to avoid cracking the plastic reservoir or stripping the sheet metal threads.
10. 10

    Reconnect the washer fluid hose
    Push the washer fluid hose firmly onto the pump outlet fitting until it bottoms out. Slide the hose clamp into position approximately 1/4 inch from the end of the hose and tighten securely with pliers.
11. 11

    Reconnect electrical connector
    If equipped with an electric pump, push the electrical connector onto the washer pump terminals and tug gently to verify a secure connection. If the vehicle uses a vacuum or mechanical washer system, reconnect the vacuum hose or linkage instead.
12. 12

    Fill reservoir with washer fluid
    Pour approximately 1 quart of windshield washer fluid into the reservoir through the filler neck. Fill to the indicated fill line or to within 1 inch of the top to allow for expansion.

Reassembly

1. Verify all electrical connections are secure and properly routed away from hot engine components
2. Ensure washer fluid hose has no kinks and is secured with clamp
3. Double-check mounting hardware is tight and reservoir is stable

Verification

• Turn ignition key to the accessory position without starting the engine
• Activate the windshield washer switch and verify fluid sprays from both nozzles with good pressure
• Check for leaks at the pump connection and hose fittings while pump is running
• Verify reservoir is not leaking from any cracks or pump grommet seal
• Top off washer fluid if necessary after testing

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