A good read...
http://www.hotrodlane.cc/PDFFILES/Lisa%20Tahoe.pdf
Items needed...
Everyone that doesn't have a late model Vortec V8 engine (pre 1996)...
Walbro 255lph in-tank fuel pump or AC Delco EP-381. The Walbro I buy is for the Buick Grand Nationals.
Replace fuel pump with high pressure pump...
I find it much easier if you remove all the hoses, electrical connections and have the fuel pump assembly in hand away from the vehicle.
Removing the bed is the easiest way IMO.
Remove the retainer ring holding the pump and fuel level sensor by rotating it counter-clockwise. Disconnect the old pump by first removing the in-tank fuel filter sock, disconnect the electrical connection from the pump and pull the pump sideways to dislodge it from the hose. Remove and discard factory rubber hose connector that was connected between the pump and the feed tube..
Install the new pump...
If your pump came with new wiring connectors that are different from your factory wiring or your old wires are brittle or cracked, it's time to solder in the new connector or use red crimp connectors to join old with new. Be sure to cut one wire at least 1/2" longer than the other so that the connections won't have an opportunity to short to one-another.
DO NOT reuse the rubber hose that came with your factory OBS pump, it won't handle the pressure and WILL eventually blow out or leak and you WILL be doing it again. Use the hose that came with the Walbro kit or fuel injection quality hose or braided stainless hose that is rated for at least 60 pounds of fuel pressure. I use the hose from the kit and I buy the hose clamps that have smooth bands with a bolt through it. I prefer not to use the worm type clamp because it damages the outside of the hose. After you install the pump in the pump assembly, install the new in-tank sock type filter. DO NOT attempt to re-use the old one you removed from your old pump. Buy a new one if you didn't get one with your pump.
Re-install pump assembly into tank. If you had to remove a bunch of black butyl sealer around the fuel pump retainer ring, be sure you get some from your auto part store or GM to seal the tank back or else you WILL leak fuel when filling or when you have close to a full tank of fuel. Lock the fuel pump assembly back into the tank by turning the retainer ring clockwise until it stops. While you are at this point check all the electrical connections and grounds. Plug your pump electrical connector back in and reconnect all hoses you removed.
This section is if you will be using a single inlet fuel rail. A return style rail will use the old style filter and return line.
Corvette fuel filter commonly used in OBS conversions if you are doing a returnless type fuel rail install....
http://www.wixfilters.com/filterlookup/ind...p;TempYear=2000
http://www.wixconnect.com/images/filters/2510_1.gif
Wix 33737
www.planetautoparts.com $37.93
GM 10299146
Purolator F55493
GF1822
Hastings GF336
PGF336
GKI GF1822
Connectors required to hook to the filter...
Dorman PNs
3/8" female connector DOR-800-121
Midway Auto Supply Online Shopping $7.36 (2 required)
5/16" female connector DOR-800-120
Midway Auto Supply Online Shopping $7.36 (1 required)
3/8" x 12" double ended male connector DOR-800-155
Midway Auto Supply Online Shopping $9.57 (1 required)
Remove the factory fuel filter by cutting the tube with a tube cutter, not a saw, immediately behind the OBS fuel filter.
Cut the return line in about the same location and bend it slightly downward to make a new slip-on connection. You can now remove all the fuel lines forward of this point going to the OBS engine. Do not remove the smallest tube(evap/charcoal canister).
Install the Corvette fuel filter...
You'll need fuel injection quality fuel hose to connect the Dorman quick connects to the old steel fuel lines. I cut both the pressure and return lines about 2" before the factory filter location. Use the rubber fuel injection hose to connect to the new filter. Use 2 hose clamps on each end of the new connections. It's best if you use the hose clamps that have a smooth stainless steel liner to protect the hose. You'll need about 6 feet of hose to connect from the filter to the fuel rail if you have an extended cab. The outlet side of the filter will require the male fitting be cut to about 4"-6" long from one end and then push it into the fuel hose and double-clamp it.
