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Hi again,
So a weird turn of events... The fuel float is sinking causing the issue. It just doesn't float! It reads fine when moved by hand and is not sticking anywhere. It is also not getting caught.
I even submerged it, picked it up, and let go for a final test, and down it went.
The plastic float part just does not float. Some say this could be caused by a leak from a small hole eroded into the plastic, however previous owner states it did this since he replaced the whole assembly from day 1 and never bothered to fix it, and visually it looks fine. So I'm thinking it's just too heavy and it sure feels like it!
Perhaps bad quality control? LOL! Bottom barrel parts... Which is probably a sign to replace the entire assembly as I can't imagine the pump is much good either...
Strange, strange day...
I ended up disconnecting the entire rod and moving the plastic piece on the assembly to full, so at least now the annoying gas warnings are gone until I can get it fixed. It worked fine and is now simply "glass half full" rather than "glass half empty". Making my empty at half, and my full at full.
I'll see if I can pull a float out of my parts bin.
Two things:
A) For any future person reading this, the inside of the metal ring that holds the fuel pump in is oddly sharp, and I gave myself a nasty 1" gash on the bottom of my thumb that thankfully, barely, closed by itself. I guess now my fingerprint will always be a reminder of the day! No bowling or typing for a while...
B) I think I am missing the inner ring under this ring, as I had to try several times to seal the ring with a combination of perfect angle and a lot of tightness, otherwise as soon as the assembly filled up with gas it was pissing all down the side of the tank and all over the ground. Unless it is really that finicky, I think I am missing a part here. The rubber ring is in place. I assume that is also the smell outside of the car (and now for a while inside the car, and my clothes, and my skin...)
All in all, a new float should fix it (like I said might just get an entire quality assembly if a sinking float is any indication of quality...), and a new ring to stop the smell.
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