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View Full Version : NB MinuteMan's Suzuki washer bottle install + wiper cowl mod



Agent☣Orange
12-23-2014, 09:46 PM
Today my buddy MinuteMan and I finally tackled his washer bottle install. This is *not* the comprehensive DIY found here (http://mazdaroadster.net/showthread.php?10461-Suzuki-Cappuccino-(Nopro)-washer-bottle-install-for-NB-(lite)-Garage-Star-wiper-cowl&highlight=suzuki&p=150430), just a quick recount of a leisurely day doing the mod.


We found ourselves looking up my old write-up from a couple years ago many times since I've gotten rusty and forgot a lot of stuff but after a lot of trial and error, we actually improved on the process and this install is the best one so far.



First order of business was to remove the Garage Star aluminum wiper cowl cover to access the space
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2380eml_zps7ea313fc.jpg


MM removed his old ugly washer tank and drained the fluid for later
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2382eml_zps0ca76156.jpg


while I prepped the new Suzuki washer bottle with the required notch
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2381eml_zps023c0c3c.jpg


Since the stock washer bottle is on the passenger side of LHD Miatas, the wiring and tubing will have to relocated to the driver side. This can be delicate because the stock fluid splitter has to be removed from the passenger side of the hood and moved to the driver side. I find that on NAs, it is often brittle and breaks while on NBs, it's still workable. If you have an NA and want to do this mod, better order the stock splitter and clips from Mazda first. Also, don't endanger the stock piece by trying to pull off the hose, just cut them first
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2386eml_zps8da8806d.jpg


and then slice them off on the workbench
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2388eml_zps36c35f8b.jpg

Agent☣Orange
12-23-2014, 09:46 PM
Then, it was off to the wiring. We cut the stock washer-pump wiring connector with a few inches of spare so it can be wired later
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2389eml_zps95a84633.jpg


and then spliced in the new extension wire along with shrink tubing and finally wiring loom. The wiring goes right into the firewall by removing a stock grommet/plug
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2392eml_zps90d125e3.jpg


Meanwhile, it was time to fabricate the brackets. As before, we used some flat brackets that come in a four-pack from Ace Hardware
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2395eml_zpsf3aba9ce.jpg


http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2396eml_zpse4fa0389.jpg


http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2402eml_zps582d1331.jpg


http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2404eml_zpsf18c5210.jpg

Agent☣Orange
12-23-2014, 09:46 PM
We had some difficulty fitting the bottle, mostly because I had forgotten how the spacers were supposed to go but came up with an even better solution. Since the bracket on inward side of the bottle (opposite the opening) only fits with no space to get tools in comfortably, we changed direction of the bolt so that instead of pointing toward the cabin, we used a shorter bolt pointed toward the engine. Problem solved.
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2407eml_zps8e7db65d.jpg


Then, it was all about getting the bottle low enough to clear the aftermarket wiper cowl cover and finish the tubing and wiring
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2410eml_zpsea69d18f.jpg

Agent☣Orange
12-23-2014, 09:47 PM
Most people would be done at this point but MM also has the wiper-cowl cover so the challenge is to create an opening for the bottle's fill neck while not wrecking the expensive cowl cover. With the cover attached at the passenger side, I was able to lift and lower the driver side to get an idea of where to drill. I was going to use my sponge method detailed in my old write-up but this time, accuracy was more important so we painted the bottle's opening with some touch-up paint which is way more precise than a sponge.
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2415eml_zpsc10f122b.jpg


The mark was successfully created but we did slightly budge it a tiny bit while removing the panel for drilling, not enough to have to redo it though
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2416eml_zps2b2f5bb3.jpg


Back to the drill press and some laser-guided goodness, we got the hole drilled but the proof was still ahead in the final fitting
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2419eml_zps481f6abc.jpg


The fit was so perfect, we just looked at each other wondering how we managed it. I was sure I was going to have to do a lot of correcting in the grinding phase but all I had to do was some slight deburring
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2421eml_zpsaf70a89f.jpg


So here is the final result, that I said looks like stock but really, it's even better! No corrections or enlarging needed, just super precise and a pleasing result.
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2422eml_zps770e7512.jpg


http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2423eml_zps91af5554.jpg



Compared to my original install below, today's is much cleaner



Old
http://i1194.photobucket.com/albums/aa375/YellowYata/Nopro%20-%20Suzuki%20Cappuccino%20washer%20bottle%20install %20NB/29mountedside2.jpg




vs.




New
http://i1194.photobucket.com/albums/aa375/YellowYata/Gearheads%20Miata%20Club%20stuff/MM%20Suzuki%20washer%20bottle%20install/IMG_2423eml_zps91af5554.jpg

jawolf518
12-28-2014, 12:02 PM
Very well done and clean install. I look forward to doing this install as well!