87 Fuel Sender Conversion

[aggie91]

Since photosuckit has made a change that does not allow 3rd party hosting without paying $400 a year, I decided to redo this how to on what I did to a stock 1987 sender to use with a LS swap. This sender is for the Driver Side Tank,

Pictured are the parts for the conversion of a 1987 GM Truck fuel sender for use with an LSx engine.

Sender: Spectra Premium, Driver side tank: #FG05M (pictured) -OR- Passenger side tank: #FG05N

Fuel Pump: Bosch #69225 (same as an ACDelco EP381)
Kit includes clamps, fuel line, isolator, wiring pigtail and clamps for install.

Strainer: Spectra Premium #STR01 (required for Fuel Pump Warranty)

Fittings:
Jegs 3/8” tube to -6 Male AN Fitting (#100551) Feed Line
Earl’s 3/8” tube to -6 Male AN Fitting (#165006) Feed Line
Earl’s 5/16” tube to -6 Male AN Fitting (#165056) Return Line

(I used one Earl’s and one Jegs because of cost, I saved a few bucks & Jegs did not have the 5/16” fitting)

[aggie91]

First step is to cut off the bulge on the ends of the supply and return lines coming out the top of the center. First picture, the left line is the 5/16” diameter return line, center line is the 1/4” diameter vent tube, and the right line is the 3/8” diameter supply line.

Second picture is after I cut off the bulge on the ends. Once the ends are cut off, de-bur the ends and the ID of each line and flush the lines with brake cleaner to remove all the metal shavings.

[aggie91]

Next, install the adapter fittings on the corresponding line. Shown here is the 3/8” Feed Line fitting. Tighten as per the manufacturer’s directions.

[aggie91]

Repeat above step for the 5/16” Return Line. For this line I had to move the support tab for the line on the sender out of the way and bend back into place once the fitting was installed. I also had to resize the line using a pair of regular pliers, being careful to keep the line round.

[aggie91]

Next install the Fuel Pump to the supply line on the sender and install the strainer to the bottom of the pump. The clamps shown on the black like are the special fuel injection clamps that hold better then standard hose clamps.

[aggie91]

You now should have a complete ready to install sender to work with your LS Swapped Square Body!


I used push lock hose and fittings with -6 ends to connect the sender up to the rails on the engine. Quick and effective. For the metal lines on the fuel rail on the intake, I used the same Earl's fitting without cutting off any of the factory line. Sorry, I don't have a picture of that set up...

My son has also done this same conversion using a Walbro 400/450 pump. the only thing he had to do different is the bracket on the bottom of the hanger needs to be cut off and a hose clamp used to hold the pump to the tube next to the pump. That set up supported his 550RWHP on his turbo'd 5.3