How to install JDM AE86 EFI tank into AE71 (not digital dash sender)

[anastasios]

Okay so I am a bit bored at work today so I will post the steps I have taken to install a JDM AE86 tank in my AE71.

This is the AE71 stock fuel filler neck setup. It has a return hose to stop fuel overflow.


I then removed the tank and this is them side by side. JDM AE86 EFI vs AE71 on right. You can see how the inlet connection differs between the two in location and type.


AE71



AE86



This is the removed AE71 filler neck. It uses a hose connection and is the same as KE70. We need to keep this hose to use in the modified AE86 filler neck


AE71 + AE86 fuel senders. Pretty much exactly the same although the AE86 uses a plug.






This is the AE86 intank lifter


And the baffle inside the AE86 tank

[anastasios]

I will get a photo of the modified AE86 neck using AE71 hose for future reference. Also the AE86 neck does not use a return for overflow, it uses a baffle in the neck, you can see an oval pipe in the tank inlet.

I just used a hacksaw with a stanley blade to cut the neck, held in a vice and it worked fine.

My next step is to sort our wiring. I would really like to try and source original Toyota plugs but need to call them up and see if they are sold separately

[Golberg]

FYI JDM AE86 fuel sender is different to an ADM AE86 sender.

Different bend in the float lever to clear the internal swirl pot.

[anastasios]

So it has been a while since I have had the time to work on this but see pic below of modified filler neck



and from the top (excuse the dirt, needs to be cleaned)

[Golberg]

I did the same as above, but instead I used the AE71 top half and welded up the little pipe.

[anastasios]

That would also work, but I wanted to show how it could be done without welding. Not many people have the skills to weld

[anastasios]

Hey all,

What cable/wire do you recommend I run for the fuel pump?

[Golberg]

Won't need anything more than 3mm.

[anastasios]

like this??

[Golberg]

Yeah that'll work just fine. You won't need anything more than that.