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the jet on mine 
| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 727   
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Banging the old washer nozzle on with a mallet got me through Christmas, just as the video above showed.
However it felt a little more wobbly than I expected, so decided to spend another day taking the dash apart and fitting the replacement CIS nozzle. It didn't go smoothly... If anyone else is contemplating this job - please learn from my mistakes. As Steve said - you can access the nut on the back of the washer jet by removing the centre console (on the later Td5 dash), which reveals the 4 screws holding the upper rear plastic panel in place.  Click image to enlarge The sun was shining right through the windscreen screwing both my eyes and the camera up, so lesson number 1 - don't have the car facing in the direction of the sun when doing this. The rear screws were very fiddly to get to - I used a ratchet socket as there is no way of getting even a small screwdriver in there due to the bundle of wires in the bottom of the compartment. Eventually I got them all out: Click image to enlarge Interestingly the plastic panel was date marked for 2002, which considering mine is a 2005 build date would suggest they had quite a box if these sitting around in the factory - hardly 'just in time' manufacturing. With this inspection hatch removed, we can finally see the screw at last! Click image to enlarge The nut on there is a 13mm nut - which will become significant in a bit. The washer pipe was pretty tough to pull off, which I guess is a good thing you don't want this coming off. Then the old nozzle pulls out to the front, giving opportunity to get a bit of protective wax under it. Click image to enlarge Comparing the two side by side - it became apparently that mine was cracked and broken. Did this happen when I banged it on with the mallet? I don't know, but I don't remember seeing missing bits of plastic back then. Click image to enlarge Note that the new nozzle uses a 17mm nut, as opposed to the 13mm nut on the old one. I did not appreciated the significance of this, and swapped up to a 17mm deep socket to reattach. Easy enough to push in from the outside, but then it was a little fiddly to get the nut started without pushing it back out onto the bonnet. Click image to enlarge It was at this point when I started wishing I wasn't billy no mates and had someone around to hold it in place. The nozzle was just spinning when trying to to it up with a socket, and as I'm not Mr Tickle I don't have 10 foot long arms to hold it myself. In trying to do it a bit at a time, running around to manually twist it back into place, it became apparent that I had damaged the felt seal on the unit, and it has all rolled up into a ball 
Click image to enlarge Fortunately I had a box of felt washers, albeit in a fetching pink shade. To prevent it from spinning again, I improvised with a block of wood, but the nozzle had to be at 90 degrees as that was the only location where it would push against the wood. Click image to enlarge Finally got it reasonably tight, and went to look at it to realise the pink washer just wasn't going to work for me, what had I been thinking? I also was having second thoughts on how suitable a felt washer was in the elements like this, would it just get wet and dissolve away? Click image to enlarge I ended up making a couple of washers out of swivel ball gasket material which I had spare. Invisible from the outside, but should provide a lasting interface between the bodywork and the nozzle body. At this point I needed to do it all again, and try and get a bit of suitable tightness on the nut. But the socket get jumping off, what on earth was going on? Well, after head scratching I figured it out - that darned 17mm nut they provided is too big (and thin) - there isn't enough room around it to get the socket square onto it when its done up tight
Click image to enlarge My solution was to fit a much thicker nyloc instead, there is plenty of thread protruding on the inside, and the thicker nut allows the socket to fit on. Click image to enlarge I also found that the aluminium nozzle is incredible soft - I hardly done the nut up tight and it was already damaging the threads, so lesson number 3 is go real gentle on doing it up. After realising this I spaced the nut out by fitting a couple of washers. The washer tube was then fitted (not too difficult to push it on, I do hope it won't jump off at some point...). Click image to enlarge then all that was left was to button it all up. I only had 1 screw left over this time... hmm I'm sure it wasn't an important one 
All that was left was to test it (which I did do before I put the dash back together!). Oh dear what a disappointment... Click image to enlarge First of all it wouldn't even push water above the windscreen wiper in its rest position! I filled the washer bottle reservoir up thinking I'd have to investigate getting a bigger squirter pump, like on the Optimill system, and it did then at least pump the water just above the wipers. As such I can't really recommend this as an upgrade - just go for the Optimill system instead. Tips for anyone else attempting this job: (a) Have someone on hand to help you hold the nozzle in place why you do it up on the inside. b) Don't use the supplied 17mm nut - the old one on the original Land Rover nozzle will fit (it turns out!), its the same thread bit at 13mm you can get a socket on it. (c) Don't get the CIS one unless you also plan to upgrade the washer pump, which I will now need to investigate (d) Do not use much torque in doing up the nozzle nut! The thread will easily strip. (e) It was a 4 hour job for me on my own, but I do have to contend with the gauge cluster on top of the dash which makes things a little slower. With a helper I would imagine this being a sub 2-hour job. 2005 Td5 90 XS 1989 V8 110 CSW |
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9th Jan 2023 5:54pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2109  
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Brilliant write up and photos đź‘Ť
So useful to myself and others - thank you. Some useful lessons learned - thanks for sharing. Sorry it didn’t quite go quite as planned, but you’ve done the hard bit and I’m sure you’ll soon be looking through a crystal clear windscreen 👍 |
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9th Jan 2023 6:33pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17540 
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When I "Optimilled" my nozzle I used duct tape to hold it temporarily while fitting the nut, it worked and was easier than trying to find someone to hold it.
I've also on occasions put a blanket over the windscreen when the sun's been a problem while I've be been working in the cab and the vehicle's parked up. Simple but effective. Remember to remove the blanket before driving of course. Last edited by blackwolf on 9th Jan 2023 7:47pm. Edited 1 time in total |
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9th Jan 2023 7:00pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2109
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Reading your second paragraph in isolation Blackwolf, I had visions of you driving in a very dangerous manner
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9th Jan 2023 7:17pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17540
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Good point!
I've edited my post to make your comment seem inexplicable!  |
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9th Jan 2023 7:48pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Good write up
 Like Blackwolf I too went for the Optimill version of the nozzle. It has been fab, until the cold spell last month that is. Something has gone wrong inside and the nozzle is not squirting well at all. I have been meaning to drop Optimill a line to ask how to service it... This has reminded me to do so... |
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9th Jan 2023 8:00pm |
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| Pacha Member Since: 23 Feb 2020 Location: North Yorkshire Posts: 772 
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Mine packed up a couple of days ago. Spoke to Optimil, who were really helpful. Fuse is ok as it's the same as the wipers (and they are working fine), and I have 12v to the original wiring harness connector so the feed to that point is ok. Checking the output from the relay that comes with the Optimil kit shows 12v so the relay is doing what it should, but the pump appears to be dead. New required pump methinks. Rgds. Chris Last edited by Pacha on 9th Jan 2023 9:48pm. Edited 1 time in total |
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9th Jan 2023 8:17pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2109
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What a cover up…(boom boom)… Sorry Hufflepuff for the temporary diversion. |
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9th Jan 2023 9:28pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17540
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A Disco2 headlamp washer pump is what I used with my Optimill installation. Easily and cheaply available due to the number of Disco2s being broken. |
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9th Jan 2023 10:30pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 727
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Does the Disco 2 pump just fit straight into the standard Defender washer bottle then Blackwolf? 2005 Td5 90 XS
1989 V8 110 CSW |
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10th Jan 2023 1:07pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17540
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No, it needs the Optimill magic pump adaptormabob device. Photos below show Disco2 headlamp washer pump on left in the lower position for the windscreen, and a Rover45 headlamp washer pump on the right in the higher position for the headlamp washers. The headlamp washers will run out before the screen as the level drops. The Rover45 pump is identical to the Disco2 pump except for the angle of the outlet spigot, and the reason why the different angle is needed is apparent from the lower photo.
The only downside of this set-up is that the Optimill adaptormabobs are a tad pricey, but they work very well. You need the mounting bracket (visible in the photos) and the extension tube that fits between the original pump seal and the new pump. If you ask nicely, Optimill will sell sell you these without having to buy the full kit (at least they did when I asked nicely). The only problem I now have with my set-up is that the reservoir can be drained completely very quickly. It is no hardship to carry a couple pf spare gallons in the back though. Click image to enlarge Click image to enlarge |
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10th Jan 2023 1:34pm |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 727
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ah bother, OK thanks Blackwolf.
It did occur to me overnight that I haven't tried the CIS nozzle yet with the engine running, which would potentially give the pump another couple of volts. Maybe that will be enough to get the screen wet? <edit> actually from the above photo, it looks like I had engine oil pressure so the engine must have been running. Oh well... 2005 Td5 90 XS 1989 V8 110 CSW |
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10th Jan 2023 1:43pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2109
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Did you replace the washer jet non return valve?
The only reason I ask is that when I did mine it resulted in a night versus day scenario - where my washer jet, as old and discoloured as it is, was like new. I didn’t expect it to make such a difference. |
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10th Jan 2023 5:20pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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No kidding, Miffy with the Optimal setup can squirt through almost as much as Phoebe with her headlight washers... But... I do love a clean windscreen. Just wish the nozzles were heated like the Freelander's  |
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10th Jan 2023 5:26pm |
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