I've got a 1990 FJ62 that had a very common problem of leaking inside the rubber grommet passenger side right where the rear window bolts to the truck. I read many threads all speaking of what a P.I.T.A. it is to fix, removing headliner, etc, etc. I went after it anyways and fixed it quite easily with some clues left in other threads. I was able to install complete new hosing from resevoir all the way to sprayer nozzle in less than 30 min. I used 15 feet of rubber hosing used for vaccum lines and washer fluid. Here it is:
Open the access panel for the resevoir in the driver side trunk, remove exterior rear vent above driver side rear wheel, remove all acess panels on rear window hatch. At rear vent pull slak out of old hose by pulling hose up and out threw the vent. If you put your hand up in there towards roof you will feel that the hose is held in place by a stay clip that the hose can simply be slipped out of(same type clips are easliy seen by looking inside rear window acess panels). Slip hose out of clip. Then at the rubber grommet (passenger side) cut the hose and slowly pull few inches of slack out of truck frame. You will find a splice valve. Remove and save. Now on the rear window acess panel(smallest one that has 2 screws) you will find an electrical connection for wiper motor. Disconnect electrical, cut old hose there as well..then pull the electrical and old hose(factory taped em together) from and through the hole at the top of the window. Do not pull electr threw grommet, keep it in. Remove tape and separate hose and elec. You will find another splice valve. Remove and save. Now you are ready to feed new hose. At the rear vent cut old hose and insert a saved valve into hose leading towards the sprayer, then insert other end of valve into new hose. Wrap tight with electrical tape. Pull old hose from where it exits truck and enters grommet until new hose feeds threw all the way from rear vent to exiting the hole by the grommet. Leave enough slack in new hose at resevoir end to feed down frame to resevoir. I was able to feed without lubing with vasoline or something. Next feed threw grommet. Then lightly tape elect connect to end of hose and feed back down rear window. Separate and reconnect electrical. Continue to feed hose to spray nozzle. From sprayer go back bout 5 inch, cut old hose and insert the other saved splice valve. Connect new hose to other end of valve. Remove remaining 10 or so inches of old hose from rear acess panel and slip new hose into the stay clips. Then at rear vent feed hose down to the resevoir. remove old hose from resev, attach new hose. Test sprayer. Re-install all acess panels and ...Ta da you is done..
Open the access panel for the resevoir in the driver side trunk, remove exterior rear vent above driver side rear wheel, remove all acess panels on rear window hatch. At rear vent pull slak out of old hose by pulling hose up and out threw the vent. If you put your hand up in there towards roof you will feel that the hose is held in place by a stay clip that the hose can simply be slipped out of(same type clips are easliy seen by looking inside rear window acess panels). Slip hose out of clip. Then at the rubber grommet (passenger side) cut the hose and slowly pull few inches of slack out of truck frame. You will find a splice valve. Remove and save. Now on the rear window acess panel(smallest one that has 2 screws) you will find an electrical connection for wiper motor. Disconnect electrical, cut old hose there as well..then pull the electrical and old hose(factory taped em together) from and through the hole at the top of the window. Do not pull electr threw grommet, keep it in. Remove tape and separate hose and elec. You will find another splice valve. Remove and save. Now you are ready to feed new hose. At the rear vent cut old hose and insert a saved valve into hose leading towards the sprayer, then insert other end of valve into new hose. Wrap tight with electrical tape. Pull old hose from where it exits truck and enters grommet until new hose feeds threw all the way from rear vent to exiting the hole by the grommet. Leave enough slack in new hose at resevoir end to feed down frame to resevoir. I was able to feed without lubing with vasoline or something. Next feed threw grommet. Then lightly tape elect connect to end of hose and feed back down rear window. Separate and reconnect electrical. Continue to feed hose to spray nozzle. From sprayer go back bout 5 inch, cut old hose and insert the other saved splice valve. Connect new hose to other end of valve. Remove remaining 10 or so inches of old hose from rear acess panel and slip new hose into the stay clips. Then at rear vent feed hose down to the resevoir. remove old hose from resev, attach new hose. Test sprayer. Re-install all acess panels and ...Ta da you is done..
