Hey mate, thought I'd chip in my two cents.

Why don't you want to use a VL pump? The only reason why you've found out that they're so commonly used in this type of setup is their suitability and how common they are. And if they are mated to a RB30 setup from factory, it's clear it'll be able to keep up with a 1.6L 4age.

In my opinion a Bosch 040 is a great pump no doubt, but it's overkill. Look the specifics up and you'll find they are designed for gnarly 500+ horsepower setups. Plus they're not cheap. If you've somehow managed to find one on the cheap then by all means go for it, but if not I wouldn't spend the big bucks on one because there's no need, a VL one will do nicely.

In my setup (16v 4age in an AE71) I've got, in order: ADM 86 fuel tank with "massaged" tongue, VL lift pump, fuel filter, surge tank, VL Turbo high pressure pump, JDM 86 fuel hard line, under-bonnet fuel filter, fuel rail, standard injectors, engine.

Not too sure as to how much research you've done, so excuse me if you already know the following, but just some general trivia for you to consider:

- don't be suckered into paying more for a VL pump out of a "turbo" as opposed to a non-turbo, they are exactly the same.
- with this setup you'll have to use a lift pump. A lift pump is a shit weak pump that lives inside the tank that only has enough power to lift the fuel up out of the tank, up to the high pressure pump.
- my setup is in my boot, and what is in the actual boot itself is the first fuel filter, the surge tank and the high pressure pump.
- high pressure pumps vibrate and are annoying as shit if not insulated, regardless of if it's a Bosch or a VL etc. When you mount it, wrap it in some rubber or something to dampen the noise from reverberating.
- a surge tank is a good idea as a failsafe. It's either that, or don't drive it hard when you've got a quarter of a tank or less, otherwise you risk starving the motor of fuel when the fuel in the tank sloshes away from the lift pump. Surge tanks are also good because the ADM tanks have no internal baffling / a cup around the pump to prevent surge (called a swirl pot) which is essentially the only difference between the two tanks.
- as mentioned already, you'll have to upgrade your fuel soft lines for EFI-rated fuel hose. This is because an EFI system is under way more pressure and standarded carby hose will simply split under the pressure. You're playing with fuel here, you want to play it safe so you don't blow up. I went one step further and installed the fuel hard line out of a JDM sprinter, which is a slightly larger diameter than the standard 4ac hardline that you're working with. These hardlines can still be bought new from Toyota for quite a reasonable price (less than $100 last time I checked) and is worth it in my opinion, to handle the extra fuel needs of a 4age. To be honest though, I doubt you'd have real troubles if you kept the standard hard line, but best practice is to get the proper diameter pipe for the application.
- all in all, at the end of the day, just pay the money for a JDM tank, if you can find one. They are the best solution to your problem, everything you need is contained inside it (baffling and a swirl pot) and it means you don't have to have a surge tank and fuel lines clogging up your boot. Make sure you get the cradle for the in-tank pump as well if you're going this option.

If you still need help, I can give you a diagram of my fuel setup and some photos if you need.

Hope that helps mate, if I can think of anything else I'll let you know.

- Alex.