Fuel and Exhaust:

Exhaust is pretty self explanatory. I had a custom setup already so to make the connection to the piping I just had to get the truck to my local pipe guy and have him custom bend the intermediate pipe. I also had him weld in the bungs for the O2 sensors and just for the hell of it, an extra bung for a wide band in case I want to tune more accurately later. Earlier I mentioned about the debacle with the flanges. Make sure you have those first if you are connecting to stock manifolds.

Fuel pump and lines. If you have a TBI injection system, the stock pump will not flow enough pressure. The 96-99 Vortec pumps work and a few others as well. I stuck with an AC Delco pump. Since I have a Tahoe, I needed to drop the tank. Not a big deal since I did that 3 years ago to change my sender. This turned out to be another process. You see I had upgraded my fuel pump years ago for the TBI, but it still wasn’t enough to pump the SFI injection on the LSX. The issue I ran into was that I had to change the plug to run the Walbro. I must have discarded the old smaller GM style fuel pump connector. GM has a part number for the pigtail (25117765) or Standard Motor Products Part # S722. Both were available online but I didn’t want to wait. I wanted the tank back up. Rain was coming and keeping the tank in my garage was fuming us out. Some research led to Airtex #WH3000. This is the fuel pump 4 wire connector that goes in between the upper and lower portions of the pump on 96-99 pumps. This wasn’t supposed to be compatible with my truck because the upper plug was different. It didn’t matter as long as the actual pump plug was the same. I matched it up in store (Auto Zone) and bought it over the counter. Then just cut out the pigtail piece I needed and spliced it into my existing setup. Then put the tank back up. I should note that the pump I had in there had a rather dirty filter. There wasn’t a sock on the bottom of the pump but there was one on the bottom of the plastic outer can. I made sure to install a sock inside the can. Factory pumps have the sock, most aftermarkets don’t, but since my tank seems to be prone to junk getting in, I will run the sock inside the can. If your factory lines are still solid, you can just get the adapters to make the connection to the fuel rails at the engine. My lines were a pish posh of repairs and rubber tubing everywhere that may or may not have been fuel injection hose. Also my fuel filter was rusted to the lines. Some engines have a returnless setup where you only need to run one fuel line to the engine. The return line comes off the back of the corvette fuel filter. My system had dual rail and it would have been simple to connect to the engine if my lines were still solid. They weren’t. I was going to run braided line the whole way but the fancy fuel injection connectors were 20 bucks a piece. Between lines, fittings and filter it would have cost me near 200 to do this. I ran rubber FI hose from a clamped connection at the fuel pump down to a 60” straight steel line which had rubber on the other end running up to a clamped connection at the fuel rail. (Quick connects at the fuel rail) I ran solid line for the straight away and spliced fuel injecton hose to make the connection between the center solid line and the repair kit plumbing. There is no difference in fuel filters with regard to the TBI injection pressures and the SFI injection pressures so you can use a stock filter part number. I went with the Delco filter as its stainless and I don’t have to worry about threads rusting together later on. As for making the connection to the fuel filer… Advance Auto parts had an elbow with 3/8” line that connected to the filter. I cut the elbow off so I just had a 3” piece that threaded onto the filter. To this I clamped the FI hose that ran up to the pump. On the other end I did something different. Adavance had a kit that was a 16” piece of 3/8” tubing and a union. The threaded end went into the pump, the union connected to the 60” piece of 3/8” I had bought prior. FI hose is expensive so I made sure to fit up the metal lines where I wanted them and then take measurements for the length of hose I would need. The feed line is 3/8” and the return is 5/16”. All clamped connections were with double fuel injection hose clamps.