I purchased a second hand Rover Mini EFI tank (from an SPI/MPI Mini) for the build for two reasons :
1) The tank is already designed for an EFI system with in-tank pump, feed/return lines and breather/vent port.
2) The 34L capacity is a big improvement over the standard 25L tank.
I had no idea of the condition or capacity of the fuel pump that was in the tank so I definitely wanted to replace it. I also wanted to retain the configuration with the in-tank pump but what pump did I need? Here are the maths for pump sizing ... the 4E-FTE engine has 295cc injectors and at 100% duty cycle, the injectors can flow 71 litres per hour : (295cc x 4cyl x 60min = 70,800cc) so using high flow pumps like a Walbro 255lph or Bosch 044 (267lph) pump is excessive.
Bosch (https://au.bosch-automotive-shop.com/ - search by vehicle) recommend their BFP0382 pump as a suitable replacement for the EP82 4E-FTE Toyota Starlet. Some more searching revealed that the same pump is also a replacement for a 2.4L 4cyl Toyota Camry, 3.8L V6 Holden Commodore & 3.5L V6 Mitsubishi Magna (all with 140kw+ engines) so I felt it was suitable for my requirements of somewhere around 120kW. The flow rate of that pump is 105lph (at 3 Bar pressure) - Perfect.
The pump was supplied as a kit with new strainers (2 sizes), plug/flylead, hose & clamps and it was a straightforward job to install the new pump. The first thing I noted though was the size difference compared to the Mini pump. The Bosch pump was much smaller in both diameter 38mm and length 87mm.
Mini pump disassembled :
The new pump was not supplied with a rubber base, so using a sharp blade I carefully cut a few slots in the Mini pump rubber base to ensure the standoffs on the bottom of the new pump were secure and the pump would not move around once fitted.
I trimmed a short length off the original tank outlet pipe and created a bead on the end of the pipe using the small bead former I made (https://mearcat.blogspot.com/2017/11/forming-smaller-tube-beads.html)
The new pump was then fitted using the fuel hose & stainless steel clamps supplied in the kit. The plug and flylead that came with the pump already had some crimp connectors attached so the other ends were securely crimped to the original Mini wiring.
The strainer from the Mini pump was in excellent condition and the inlet port diameter of the Mini & Bosch pumps were the same, so I re-used the strainer.
I did not have the wiring loom or electrical connector to plug into the tank so I planned on using a combination of spade connectors and another plug to create an adapter for the fuel tank, however after visiting my local electronics store Jaycar and buying a random 2-way automotive plug (Jaycar PP2062 Plug) it was by complete coincidence the correct plug for the tank!
In regards to the fuel pump wire gauge/size in the factory Starlet wiring loom, because the Bosch pump was a replacement for OEM Starlet pump and not an upgrade, I don't expect it to draw significantly more current so an upgrade to power wire gauge to the pump would not be necessary.
1) The tank is already designed for an EFI system with in-tank pump, feed/return lines and breather/vent port.
2) The 34L capacity is a big improvement over the standard 25L tank.
I had no idea of the condition or capacity of the fuel pump that was in the tank so I definitely wanted to replace it. I also wanted to retain the configuration with the in-tank pump but what pump did I need? Here are the maths for pump sizing ... the 4E-FTE engine has 295cc injectors and at 100% duty cycle, the injectors can flow 71 litres per hour : (295cc x 4cyl x 60min = 70,800cc) so using high flow pumps like a Walbro 255lph or Bosch 044 (267lph) pump is excessive.
Bosch (https://au.bosch-automotive-shop.com/ - search by vehicle) recommend their BFP0382 pump as a suitable replacement for the EP82 4E-FTE Toyota Starlet. Some more searching revealed that the same pump is also a replacement for a 2.4L 4cyl Toyota Camry, 3.8L V6 Holden Commodore & 3.5L V6 Mitsubishi Magna (all with 140kw+ engines) so I felt it was suitable for my requirements of somewhere around 120kW. The flow rate of that pump is 105lph (at 3 Bar pressure) - Perfect.
The pump was supplied as a kit with new strainers (2 sizes), plug/flylead, hose & clamps and it was a straightforward job to install the new pump. The first thing I noted though was the size difference compared to the Mini pump. The Bosch pump was much smaller in both diameter 38mm and length 87mm.
Mini pump disassembled :
The new pump was not supplied with a rubber base, so using a sharp blade I carefully cut a few slots in the Mini pump rubber base to ensure the standoffs on the bottom of the new pump were secure and the pump would not move around once fitted.
I trimmed a short length off the original tank outlet pipe and created a bead on the end of the pipe using the small bead former I made (https://mearcat.blogspot.com/2017/11/forming-smaller-tube-beads.html)
The new pump was then fitted using the fuel hose & stainless steel clamps supplied in the kit. The plug and flylead that came with the pump already had some crimp connectors attached so the other ends were securely crimped to the original Mini wiring.
The strainer from the Mini pump was in excellent condition and the inlet port diameter of the Mini & Bosch pumps were the same, so I re-used the strainer.
I did not have the wiring loom or electrical connector to plug into the tank so I planned on using a combination of spade connectors and another plug to create an adapter for the fuel tank, however after visiting my local electronics store Jaycar and buying a random 2-way automotive plug (Jaycar PP2062 Plug) it was by complete coincidence the correct plug for the tank!
In regards to the fuel pump wire gauge/size in the factory Starlet wiring loom, because the Bosch pump was a replacement for OEM Starlet pump and not an upgrade, I don't expect it to draw significantly more current so an upgrade to power wire gauge to the pump would not be necessary.
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