[Nova_Cobra64]

Part 1 - Basic fuel system requirements

The first step to getting started on your fuel system is first determining what you have. The LS fuel system has specific pressure requirements, which means the fuel pressure is regulated and unused fuel supplied by the fuel pump is going to be returned to your fuel tank. As such, you are going to need a fuel tank that will be able to accept fuel return. There are two types of fuel systems from the factory. The first type is equipped with internally regulated fuel rails. In this case there is a second connection on the fuel rail for the return fuel. The second type will just have one connection on the fuel rail, and this system requires the fuel to be regulated at 60psi within your fuel supply system. The components and specifications of both systems are identical with the only difference being the addition of the regulator in the second type of fuel system mentioned. I will post a basic overview of the parts needed to build your fuel system now, specific part numbers will be added in Part 2.

Fuel Pumps - Your fuel pump will need to put out a minimum of 60psi at a rate of flow that is going to vary by application (ie: 40 gallons per hour for the LS3 and 50GPH for the LS7). The fuel pump can be either an in-tank or external in-line pump. While it could be subject to disagreement, there is no "best" route. Both systems have their benefits, such as the in-tank pumps being said to last longer due to being cooled by fuel or the external pumps being easier to change if the need arises. The option does exist to replace stock in tank pumps with one meeting your system's requirements, information on this will be included futher in this guide. If the factory sender does not have provisions for an in-tank more often than not an in-line pump will be used for the sake of simplicity.

Fuel Filters and Regulators - For those who need to build a fuel system regulated to 60psi, the most cost effective method is running Corvette filter/regulator (GF822, jobbers available). The GF822 will regulate your fuel system to 60psi and is equipped with a 3/8" male quick connect for fuel in, 3/8" female quick connect for fuel out, and a 5/16" male quick connect for the return fuel. Because this filter has to be placed after the fuel pump, some people opt to install a fuel filter prior to the fuel pump for added protection and extended life of the more expensive filter/regulator.

Fuel Lines - Because your fuel system is going to be running upwards of 60psi, you are going to want to make sure that any fuel lines and fittings being run after your fuel pump are going to be capable of handling such pressure. From there it comes down to personal preferance. Steel, stainless steel, and aluminum hard lines with -AN style fittings are one option. If you go this route, there are 2 items to note. The first is that -AN style fittings require a 37 degree flare, a basic flare tool can be had for around $30 and making the lines is as simple as anything else you will experience in the swap. The second note is if you opt for stainless hardline, the flare tool required is significantly more money ($250+). Braided style hoses are the other common type of hose used for LS swaps. There are interal and external braided hoses available in a variety of colors that are also very easy to make. The manufacturers of these hoses all offer fittings that work specifically with their lines. I've seen some mention of guys having used nylon fuel line (which is pretty common from the factory now), and some having used fuel injection rated rubber hose with fuel injection clamps. The use of basic fuel injection hose and clamps is generally not preferred due to safety concerns. Further to this I've read there are NHRA restrictions on barbed fittings and rubber hose, if anybody can clairify this please PM me.

Fittings As mentioned above, the use of -AN style fittings is extremely common with LS swaps. -AN is a unit of measurement where -01AN = 1/16", so as an example -06AN is for 3/8" line. -AN fittings come in a variety of colors. JIC fittings are also 37 degree and can be used as a cheaper alternative but will not come in any special finish. The 3/8" and 5/16" style quick connects for fuel supply and return are available from a variety of manufacturers to work with -AN fittings and with nylon line as well. One item to pay attention to while assembling a fuel system with -AN fittings is many pumps and filters have metric and NPT threads and will require fittings to cross over.

Misc Items There are some small items to consider as well while you are building your fuel system. You will want to make sure to order the necessary supports for your fuel lines or hoses. A fuel shutoff valve can also be included as a theft precaution or to make your life a little easier while changing fuel filters.