06 LQ9 into 89 Suburban Fuel Delivery/CA Smog Issues

[socoinslo]

Well I thought I would update my progress on this swap so far. I finally got the 06 LQ9 picked up and brought home, then I got the old motor out, swapped inn a cross member from TNA which fits around the new motor better, then got the new motor in place. As suggested, I picked up a fuel tank from a 99 suburban to try to swap in, but there's just no way it is going to work under my 89. I went with the 99 suburban because it was the closest to my original shape and size. So now my biggest obstacle for this swap is still the evap/emissions stuff. Here's some pics of the progress:

[socoinslo]

Motor in the truck:

[socoinslo]

So now that I know that I have to use my original fuel tank, I am going to have to somehow add the pressure sensor and fuel level sensor to my original sending unit. Any ideas??

[kewljay223]

get the newer style donor tank and cut out all the holes (sending unit, and two check valves) and weld them onto your original tank. that way the tank will still fit and you will have all the provisions and required parts for the newer style system. this assumes you replace the sending unit opening you have now. the pro to this is that you wont have to add the pressure sensor as its built into the newer sending style sending unit. the con is that you will have to remove the old sending unit which will render your gauge useless since the newer style cant run your gauge...

TWO options:

1) you ADD the newer style opening to have both of the sending units in the tank, which will probably be very difficult due to the baffles inside for fuel slosh.

OR

2) you go ahead and replace the opening with the newer style and the add your old float (just the float) inside somehow in order to run your old fuel gauge.

i know what i just said sounds really confusing but it makes sence if you read it a few times. lol anyway, thats kinda what i did and is how i would do it if i did another cali swap again. im running two floats in my tank. and while i was in there, i added a second pump for my future mods. but in doing that, i had to drill holes and add wires. doesnt seem like a big deal until you have to find a way to seal it up!! and it has to stay sealed and be COMPLETELY sealed for the evap test to pass... hence my point of just welding all the provisions in your tank that way everything just plugs right in and seals like it should PLUS it will look factory to the ref which is what you want. just know though that if you go with option 2, you will still need to get two wires in the tank and seal it which is why option 1 is nicer but harder to do.... if you still go with option 2, make life easy and fork up the cash for this...http://www.racetronix.biz/itemdesc.asp?ic=BCWS-001&Tp= trying to dick around sealing up your own holes is not worth it. trust me!! pick that up, looks factory and allows two extra wires for a second pump if you wish.

my only concern about welding the tank is the inner coating to protect against rust. never dealt with that before so idk anything about it.

i would post pics of what i did but i didnt take any. lol sorry. but dont ask what i did tho cuz im lucky i passed with the way i have it (i almost didnt pass because of it) and im sure your ref will say no. go with anything i posted above and im sure you will be just fine. def not a walk in the park tho...

[socoinslo]

Sweet! this is exactly what I have been considering doing. I have been wondering how in the world you went about it. I think I might just swap the holes out for the sending unit. I am a little worried that the newer style sending unit will be too long to seat in the tank though. The newer tank is deeper than the older one and the sending units normally sit right at the bottom of the tank. Im going to go pick up a used '99 sending unit and see what I can come up with.
I wonder if I can mount the old float to the new sending unit somehow and then just run that wire bulkhead adapter to it.

[jaysonolson]

If you use the fuel rail on the drive side of the 2001 through 2003 you can used the factory fuel return system of the suburban and just put a 255 gph pump in the original tank sender unit.