Fuel System Conversion

I pulled the fuel pumps from the 320i and adapted them to fit the 2002. It looks like the 320i fuel pump puts out the same pressure as the e30 m3 fuel pump. It sounds odd that a 100hp motor would use the same fuel supply as a 200hp motor, but the numbers seem to add up. The 320i pump fits the 2002 gas tank perfectly, though its one inch shorter than the 2002 pickup. This could cause fuel starvation problems when the tank is low. I'll have to look into adding an inch to the bottom of the fuel pump pickup to made it go all the way down. In the meantime this should be good a good start. Here's the 2002 pickup (left) and the 320i pickup (right) for comparison:

I used the e21 high pressure pump and mounted it in the trunk. I'm using the factory hard fuel return line as the supply. I replaced the 4' of soft line that goes from the trunk to the hard line in front of the diff with some new high pressure fuel line. The stuff is rated at 100 psi working pressure, 900 psi burst pressure. The system is supposed to run at about 50psi. I fabricated up a mounting bracket to put the high pressure pump and fuel filter (from a e30 318i) close to the fuel tank. I still need to source the right size hose that goes from the in-tank pump to the high pressure pump. I wrapped the 320i fuel pump in some closed cell foam to help reduce the vibration and noise from the pump, thought it could just act like a blanket and keep the thing too hot. The filter has a pad of the same foam behind it to help with vibration as well, then its all strapped in with zipties. Its bolted in using the factory square hole that is in the rail.

I have the connectors for the pumps from the 320i, though I don't plan on wiring the electrics for the pumps until I get the megasquirt together.