Open Road

Has anyone removed their big washer fluid tank and used the small tank below the windscreen instead? Any suggestions on how to wire it to work with the wiper lever?

Me? No. Wash tank is plenum volume for coolant for intercooler.

As for wiring...

What I would do is make a 5-foot (ish) extension harness from the plug connector for the tank pump to the intensive washer pump.

Sourcing the pins and connector bodies will take some time but they are all probably on DigiKey.com.

i did it years ago on the orange one, as Dave says just need to run a length of twin core wire from the wiring going to the main washer pump and plug it into the intensive washer pump.
pretty sure there is enough length of wire to cut the connectors off leaving just over an inch of wire still on them so you can keep them so if you or somebody else in the future wants to put it back to standard, they can
i was in weight saving mode on the orange one, so also just removed the main washer bottle and all pipework for the headlight washers at the same time

think i have some pictures of the wiring somewhere.
cheers
Phil

thought i had some pictures but cannot find them
but also a good time to remove the small bottle and give it a good clean inside, will be full of very old water.
and also a good time to change the 30+ year old rubber seal that seals the motor to the bottle, part number is 431955465B.

i personally also removed the washer jets and removed all the pipework from inside the bonnet, one way valves and joins etc, i bought a couple of meters of new washer pipe 99918172240and ran it from the motor, through a Y piece and then to the washer jets.
now all clean / new nothing to clog the washer jets.
cheers
Phil

Thanks Worf and Phil for the good suggestions!
I will make a harness from the tank pump to the intensive washer pump.
The intensiv washer tank is already cleaned. Might look into replacing the pipes at a later stage, if it doesn't work as it should.

I was just looking into the piping hidden in the hood cowl area.... If/when you look into the piping, note that the piping configurations changed through the years. The very early configuration (without intensive wash tank) and the GTS configuration (also w/o intensive) being the simplest (and therefore less problematic in my view). The intensive washer tank location also changed for 87-91. The other option to consider is whether to use heated nozzles (84+) or not - the heated nozzles are larger from what I understand, but I dont know if that means different size mounting holes. PET diagrams follow.


^^^^^ 1978-1982 Diagram ^^^^^


^^^^^ 1983-1986 Diagram ^^^^^


^^^^^ 1987-1991 Diagram ^^^^^


^^^^^ 1992-1995 Diagram ^^^^^