Hello:
Thanks for giving some input here, it is all learning in some fashion.
The fuel systems on these truck is not reliable in any real way. The Ford system, at least the more recent ones have a step-up (2 pump system) which I have to believe is 800% better than the GM version. These trucks are well- known for the fuel pump issues. The original may last forever but once they start going it is a crap-shoot each day on if the truck will start. In 2005 I changed the pump 3 times, the last time it lasted 1 month to the day. A very poor design that has not been re-engineered, regardless of brand. This last pump is now another Delco, I have also had Carter's and Re-tech's.
That said.....the only other weak spot in this system that I know of is the FPR. In time it will be an issue. I have nearly 200,000 well maintained miles on the Suburban. With everything else as it should be the only thing I can come back to is that the FPR is bad. The pump is new, the pressure is well above 60, (good) and with the local parts stores affirming that they do sell FPR's often enought tells me that there is a possible cause of my problems.
I have a 1997 Sub (almost 200,000 miles) and a 1993 truck (207,000+ miles), 6 pumps into the 97 and 3 into the 93. I love the trucks they do what I need them to do .... when the fuel systems work. That is the only problem I have every had with either of these trucks.
I need to know if the FPR is under the plenum for sure. If in fact it is, once again GM complicated things when they didn't need to.