VW Polo Washer & Headlight Spray System Failure Fix

Had the exact same fault on my 2005 VW Golf diesel. Since I have some experience working on cars, I first checked for obvious issues like frozen fluid or blockages, but found nothing. The malfunction turned out to be a faulty cable connection between the washer pump and relay. The headlight cleaning system stopped working first, then the windshield washers followed, exactly like your case. A loose connection was causing both systems to fail since they share electrical components. Took it to my regular workshop after my initial checks. They traced the fault to corroded wiring near the pump assembly. The repair included replacing some cables and a relay, totaling 165€ including labor. Before suggesting specific fixes, could you provide: Has there been any water damage or flooding in the engine bay? Do you hear any clicking sound when activating the washers? Did you notice any fluid leak under the car? When exactly did the headlight washer system start failing? This information would help determine if your issue matches what I experienced with my Golf. These systems are quite similar across VW models from that era.

Thanks for checking. Yes, I hear a faint clicking when activating the washers. No visible leaks under the car, but I did notice some dried washer fluid residue near the hose connections. The headlight washer fault started about 3 months ago during the last service at 129802km. After inspecting closer today, I found the main hose from the washer pump looks cracked and brittle. Could explain why both systems went down, since they likely share the same pump and pressure. The LED fault light for the headlight washers comes on intermittently too. Will try replacing the hose first before looking at electrical issues. Hope this cheap fix works before spending on a new pump or wiring repairs.

Thanks for the additional details. Your symptoms match my Golf experience exactly, it also showed cracks in the main pressure hose. Looking at the dried residue location and the clicking sound, you are definitely on the right track suspecting the hose. When my headlight cleaning system failed on my Golf, I initially focused on the electrical malfunction due to the LED warning. However, replacing just the hose fixed both systems since they share the same pressure circuit. The brittle hose was causing pressure loss, making the system think there was an electrical fault. The hose cost me around 45€ and took about 30 minutes to replace. Make sure to check all connecting points while doing the repair, the old hose fragments can clog the system. Since your mileage is similar to what mine was, it is likely just normal wear causing the hose deterioration. Also inspect the pump housing for hairline cracks while you have access to it. These can develop over time and cause similar symptoms but are harder to spot without removing the hose. The fact that both the windshield washer and headlight cleaning systems failed together strongly suggests a shared pressure issue rather than an electrical problem. Let us know how the hose replacement works out.

Thanks for the detailed information about the Golf comparison. I found the cracked hose today and replaced it for 45€. You were right, it fixed both the windshield washer and xenon headlight cleaning systems completely. The leak in the old hose was causing pressure loss which triggered the fault warnings. While replacing it, I cleaned out some debris near the pump connections that had built up from the leaking fluid. The clicking noise is now gone and both systems work perfectly. No more fault lights on the dash either. Really glad I checked the hose connections first before spending money on electrical repairs. For anyone else reading this, definitely inspect the washer fluid hoses if both systems fail together. The pressure loss from even a small leak can affect everything. Will keep monitoring for any residual issues but so far everything works like new. Thanks again for helping me avoid an expensive workshop visit.