Hello all,
A few days ago I did a write up on the the headlight washer retro fit to a aftermaket steel bumper.

Refit factory headlight washers to offroad steel bumper

Today I picked up the Check valve from the dealer so I could hook up all the hoses correctly. I got it all hooked up and ready to test. The headlight washers will only on work under the following conditions, per the owners manual. Note: All my windshield and read washers work correctly.

1. Headlights turned on
2. 3rd time window washer is used they will come on to wash headlights.
3. All those conditions were met.
4. 20amp Fuse blown in under hood fuse box 2x

Here is my problem, the 20amp fuse under the hood blows each time I try. I've run through 2 fuses testing. So is it a bad pump motor? I have not put a volt meter on the plug yet to test if the motor gets voltage of 12v each 3rd attempt. Also I had the motor blocked off for a long time while I had no headlight washers attached. I think the plug to operate the motor was unplugged most of this time. Could this have burned out the pump. I have one on order from eBay but wanted to know what other folks more experianced in electronics thought.

 

Check to make sure there aren't any wires "grounding" out on the frame or other metal bits. If you unplug the headlamp pump does the fuse still blow? Most likely a bad pump though, and 20A is the correct fuse w/ or w/o headlamp wash so that part's def right. Check both windscreen and headlamp pumps as they're all on the same circuit.

 

It is probably the pump motor. When my A/C condenser fan motor was seized and burned out the fuse kept blowing.

The Headlight washer has its own fuse #4 4th back from the front in the fuse box under the hood. The windscreen washer fuse is 19 15amp(blue) in the main foot well fuse box. And the windshield wipers work fine.

 

check to make sure they arent covered in ice. if they get blocked by ice, it puts more strain on the pump/motor to push that de-icer/washer fluid, happens to me once in a while if its solid ice buildup, and then pops the fuse for the headlight pump, but the windshield and rear window ones work fine