After playing around with the aging headlight washer pump on my '92 Gen 2 one too many times, I found a very high output washer pump from BMW for the older Seven series that is a very straight fit with little mods need. Part # is 61-67-1-382-085, list price around here is $73. This is better than the $125 that Mitsubishi wanted for their no-longer-available pump anyway. <img src="/forums/images/graemlins/notooth.gif" alt="" />
This pump has two output nozzles or fittings, so unless you're planning to get trick and spray your fog lights or off-road lights with their own nozzles, you'll need to block off the tan nipple on the pump with 2 clamps, and a bolt shoved into a small piece of rubber hose as a stopper.
The black nipple seems to flow more fluid/pressure, so use it. The pump body is the same diameter as your old Monty pump, so you can reuse the steel mounting bracket. The BMW pump is just longer, but we have enough room at the reservoir area, so no problem there.
The 90 degree Montero hose will mate up with the black fitting/nipple of the BMW, as it's the same diameter like the stock pump. The inlet or suction fitting of the pump will fit in the stock rubber grommet of the Montero washer reservoir, but use a dab of silicone grease as it's a tight fit. Align the BMW pump to match your previous pump, then tighten the bracket.
I cut the wiring of the old pump to reuse the Monty connector, this means you can connect to the stock harness easily on one end, but you will need to find 2 round female electrical pins to solder onto the old pump wiring to mate with the BMW pump. I can't say just what diameter these pins are, they look like maybe 2mm round female pins, much more common for Euro cars than on a Japanese vehicle, so either try Radio Shack, or a Euro car dealer/shop to obtain the correct 2 pins. I soldered the pins onto the stock Monty wiring[I have odd electrical pins from a decade of working on BMWs previously], checked for polarity on the BMW pump[it's not marked one way or the other] and slid the pins home onto the pump. Added some heatshrink on the outside of the pins too as well as some silicone sealant to keep them locked into the pump.
Works great, huge improvement over the Monty pump[even when it did work] Sorry that I don't have any pictures, I did this at work after hours a few weeks ago, no camera. Maybe Bretwalda and I can hook up to take some pictures for everyone later this year. <img src="/forums/images/graemlins/cheers.gif" alt="" /> Houston

I'm all for hookin' up, and all for taking pics.

Great find. <img src="/forums/images/graemlins/kewl.gif" alt="" /> Nothing like improving on one of the Monty's crown jewels <img src="/forums/images/graemlins/smile.gif" alt="" />

J C Whitney has a universal kit for under $25? that you could modify for the headlights.
Bob Shaw

I haven't seen this pump Bob. Are you sure it will handle the much larger flow of fluid that the headlight washers require to work with?. Most windshield pumps only have a tiny output hose, not the 5/16" to 3/8" [8mm/10mm] output of most headlight washer pumps. They also won't usually budge the in-line check valve that most headlight washer systems use. <img src="/forums/images/graemlins/shiner.gif" alt="" /> Give us part number so we can check it out with J.C. Whitney

Look under Windshields, washers,pumps in J C Whitney. It is a replacement for the tank and pump for windshields. I am not familiar with the headlight washers. Are they much different? Seemed like an easy repair or addon for $15-$18.
Bob Shaw

I think the HL washers flow enough to actually try to "wash" the lights, whereas the WS washers more "wet" the windshield and the wipers "clean" it. Hence the HL washer flows considerably more and at a higher pressure. As a point of reference, take a look at the sizes of the pumps and reservoirs. The HL is bigger in both cases.

Especially on the Gen2 which uses 2 nozzles per headlight. You can suck the resevior (over a gallon) dry in a few seconds.

But wouldn't you have to get the headlights really dirty to need to do that? <img src="/forums/images/graemlins/cyclops.gif" alt="" />

When you dive into a mud puddle that is hood deep, the lights do get that dirty.
Gee I wish I had the headlight washers. It beats carrying the pump up 2 gallon bottle with spray nozzle.
Bob Shaw