I got the hard fuel lines out of the car and the braided hose in on Thursday afternoon. I reset the EFI to factory settings and went through the setup process. Took it for a drive and it's no better than before so that was wasted time and hose.
I spent over an hour on the phone with MSD tech support, including about 45 minutes on Friday with the "MSD EFI guru". Seems like he is stumped too, the only thing he recommended was to change the IAC, the idle air control, which was acting strange sometimes. So I ordered one from NAPA, picked it up yesterday, and installed it this afternoon. It didn't make any difference at all as far as I can tell, so I'm going to call him back on Monday. If you rev it up over 2,000 RPM or more and then let it back to idle, it will almost and sometimes die for a few seconds before it recovers and goes back to idle speed. While at a steady speed with the engine turning 1,800 to 2,000 RPM, sometimes it surges like you are giving it more then less throttle. It has also started backfiring, mostly when shifting from 1st to 2nd and sometimes on the 2nd to 3rd shift. It never did that before, and is a sign of a lean mixture, or possible an exhaust leak. When I had it up in the air, after I got the fuel line installed, I started it up and checked the entire exhaust system for a leak and didn't find one.
If I can't get this sorted out, I'm just going to pull it off and get either a FiTech or Holley unit and put that on. I'm tired of messing around with this unit and want it running right so I can drive it without fighting it all the time.
I guess if I ran a return line to the tank, I could install a pressure regulator and slap on one of the Holley cabs I have setting on the shelf, it couldn't possibly be any worse.