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Discussion Starter #1
I received a replacement headlamp washer unit, but I noticed that the top portion will easily pull out. When under pressure (tested with an air compressor) it rises properly, but will also pop out. On my old unit the top could be withdrawn by hand and was clearly attached to the underlying mechanism.

The photo hopefully makes it a lot clearer what I'm talking about:

 

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What pressure was your air compressor set to?

If it was at the standard 90-120PSI, I could see it launching the squirter across your garage.

The washer pump pressure will be much much lower than what the air compressor can do.
 

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Discussion Starter #3
Ha, definitely not 90 PSI. I only turned it up until I saw any movement at all, which was probably 10-20 PSI. It also came out the same way before the test. You can pull it out with just a few pounds of force with your fingers, but the old one is firmly fixed.

I first did a bench test with a spare Lotus headlamp washer pump I had, but I don't think my benchtop supply was powerful enough to pump it. Anyone know what voltage it's supposed to run at? I only did 12V, and my supply can only do 1A. The circuit diagram actually lists something like "IGN + 15" but I'm not sure if that actually means 12V + 15V, and I didn't want to fry anything even if I could get a PSU that did 27V at whatever amperage required.

It's a bit of a moot point anyway, as I realized one of the nubs on the top is broken off, so it wouldn't even be able to clip into the headlamp unit washer cover.
 

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The headlamp and windshield wiper motors are on the same fuse, and that fuse is 15amps. I doubt it is anywhere close to that amperage for just one of the motors, assuming it's 50%, that'd be a max of 7.5amps for start up current. Once it's running, it will be a lower amperage draw. You could hook your meter in line with that pump and see what amperage it is drawing. Either way it's moot since your clip is broken, but it would be fun to see if the top shoots out of the housing!
 

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Discussion Starter #5
Even at 7.5 amps that's way more than my current benchtop supply can provide, so that'd explain why nothing dramatic happened with the motor running. Once I have the wheel and liner off I can do testing in situ, though I lack the proper connectors for the wiring harness. I had to use some spade connectors that were difficult to keep in place.

I have no doubt that enough air pressure would blow that top off. It would be amusing!
 
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