Fuel pump hanger won't seat. what's wrong???

[Al_C]

It's a long story that you will hear about soon enough. For now, the issue is getting my new pump back into the tank. Old pump was a 155; this one is a 190. Essentially the same physical dimensions. Same hanger as before. New filter pouch on the bottom.

It doesn't want to seat. It goes into the tank, but won't go the last inch or fraction thereof. The filter pouch is essentially the same, no? I believe the orientation is correct, but I suspect this is where you will tell me I messed up. I'm hoping one of you will know why this won't seat and show me the error of my ways. (please) I've done a pump swap before and it was no big deal. This one seems to be. Here are the photos:

https://thefactoryfiveforum.com/attachment.php?attachmentid=173186&d=1664476897
This one shows the two filter pouches. Old on the right.

https://thefactoryfiveforum.com/attachment.php?attachmentid=173185&d=1664476865
I believe this is the correct orientation. No?

https://thefactoryfiveforum.com/attachment.php?attachmentid=173184&d=1664476853
Another photo of the proposed orientation.

There must be a baffle or something that is in the way at the bottom of the tank? Thanks for your help!

[Papa]

Al,

Look inside the tank as you insert/position the pump and you'll see how that screen filter needs to be positioned/clocked to sit in the baffle area in the tank.

Dave

[mladen]

As papa said, you're probably not seating in the baffle correctly. Your setup looks right. If you have the ability, take out the fuel filler neck, you can then also see from the side how things are seating.

[Al_C]

It just keeps getting better. This was supposed to be a "little job", not a "big job". Tried a couple of different angles on the filter pouch, and still haven't gotten it seated yet, but will persevere. HOWEVER, in the process of in and out multiple times, I have managed to scape one of the electrical leads, so there's a little bit of bare metal showing. I had been able to plug the new pump in without changing the wiring, but now I have a scrape to deal with. Here are my options:

1. cut the offending wire, put on a new butt connector and fuel resistant heat shrink. Considering that I don't know if the heat shrink in my cabinet is fuel resistant or not, I have to get some, someplace.
2. Find some fuel resistant sealant that I can apply to the wire without cutting it. I don't know if such a thing exists, but if it does, I'm hoping someone here will know.
3. Forget that this ever happened and just stick it back in the tank. They say that gasoline doesn't conduct electricity, but I'm not sure this is a good idea.

Open to your continuing suggestions!

[Jryasko]

McMaster has fuel resistant heat shrink AL

[mladen]

How easy would it be to replace the wire(s) completely?

[ChasNMe]

bad wires get worse . . . . cut wires eventually come apart. if current is flowing when that happens, in your tank . . . you get the idea

[Al_C]

I found fuel resistant heat shrink at mcmaster carr, at Jim Yasko's suggestion. The fuel pump kit came with an electrical connection and two wires, so I'm replacing the plug and two wires. I think it's the right way to fix it. It's not that big a deal, but it is one more PITA. Whatever. The good news is that I can pick up the heat shrink today! I don't have to wait for it to be shipped!