I'm trying to install my new in-tank fuel pump for my 91 Formula TPI.

Any time I am messing with getting the installation finished up, the part of the power line inside the tank keeps falling off. It's got three prongs that it plugs into and I can get it plugged in okay, but I'm afraid that once I'm running again I'll hit a bump and lose the power to my fuel pump, and that would suck.

Problem 2.

I cannot get the outer ring to turn and seal the tank off after installing the pump. I'm trying to explain this but words aren't coming to mind. I can't get the plate which the metal gas lines run into to stay down to seal the tank off. What am I missing?

Thanks,
David

 

Here is a picture of the electrical connection I am referring to. It's the one the screwdriver is pointing at with the yellow cap. I pried it off with the screwdriver but now I can't get it to stay connected to the plug on the underside.

Yes, I did the cut-the-hole-in-the-trunk method, and no comments about how badly it's hacked up. :-) Once it's completely done I'll recut a perfect square and file it down, and make an access panel and label it "Fuel Pump". But, one thing at a time. :-)

 

Please, anyone? I can't drive my car and I need it...

 

Wow; I've never seen a hole cut like that. How'd you cut it and not go thru to the tank? (I've had to change the pump twice, and had to drop the tank twice... what a pain.)

Why did you pry the connector off in the first place? I wonder if you broke something.

 

The hole looks actually worse than it is. Looks like I took a chainsaw to it. I actually just drilled holes and cut the metal and then pried it back like a can of tuna using vicegrip pliers. I'm going to cut clean edges with some tin snips or something and then file it down to make a much nicer cut after I'm done.

Why did I pry the connector off? That's a good question. I suppose I didn't have to. :-( Other than to make sure I didn't cut the electrical lines on accident. I guess I could superglue/epoxy the yellow connector back on, but how am I going to get the electrical connector on the underside to stay on

I'm a friggin' genius. :-)

I guess I could try supergluing at the bottom of the pronged connector and see if I can't get that to work. Still doesn't solve my problem of getting the thing to seal to the tank though. Blah.

 

Try looking at the thing to see if you can find something broken on the connector; I can't remember "exactly" what it looks like, but is it a common GM weatherpack connector that you could find at a parts store? Or is it more of a "pass-thru"? Maybe you could make your own pass-thru...some wires, thru a grommet (where the connector was), and fill the grommet with something that resists gas? I think Ultra Copper gasket maker (in a tube) is gasoline resistant?? Hopefully the gasketmaker or grommet doesn't somehow fall thru into the tank... maybe you could lay some fiberglass matting over the grommet as a "base" to lay the ultra copper over?

 

Oh, and you just have to compress the new o-ring gasket completely. It's thicker than the one that was there, just because it's new. You'll have to push down on the lock ring with one screwdriver while you use another one to turn the ring to a lock position.

But first, ya might want to pull the sending unit out so you can fix it on a bench, though.

 

Sorry, I'm not exactly sure what you mean. I can take a picture later today when I get home from work if you'd like. It's just got three prongs on the yellow end, and "four" ports on the other end but one is a "dummy" port I guess you could say. I have it plugged in correctly though, there's only one way it will fit.

Well, I'm hoping that I haven't _already_ knocked something in the tank since it doesn't seem to want to stay. Is that really dangerous though? There's nothing it could get sucked into because of the strainer that hangs into the tank, and if there were something it'd obviously be resistant to gas and wouldn't break down into the gas, so I should think it wouldn't be a problem.

 

Okay. Thank you!! I guess I just need to push harder. I've been trying to use my bare hands to lock it together like an idiot, so I'll use the two screwdriver method. Now that I think about it..duh.. Thanks for the help.

 

I'm just wondering if you stretched a piece of it that was originally "tight", and made the connector lock together, or broke a little plastic clip, or...

Dangerous for who? Dangerous for the pump, no. Dangerous for you (gas fumes collecting under the car), yeah. But you know what I mean about making your own pass-thru, right? That's what I think that broken connector is/was... a handy way to pass wires thru the metal sending unit top. If you can replicate it somehow... just make sure you get it to seal off.

Or.... visit a junkyard, and do the same job to it as you did yours, and get a new sending unit

 

Sorry, I should clarify. I didn't mean dangerous as far as not being sealed goes, but rather having something floating around in the tank.