Over the weekend I picked up a fuel pump from a local salvage yard. They told me it was from a '96 Sunfire like mine. The one I took out had metal fittings, the one I put in has plastic fittings. The previous owner had had pump issues so he cut an access hole under the back seat so we wouldn't have to drop the tank. Pretty handy really. My question is about the rubber gasket that fits around the pump inside the tank. The gasket on the new one seems too big. It will not fit inside the tank to seat the pump without looping down. Could the pump be from a different year or maybe the 2.4 instead of the 2.2? The car runs great, but is not safe to drive since it is not sealed and venting gas fumes into the car, plus not knowing this I filled up the tank yesterday and gas poured out of the top of the tank around the pump. Does anyone have any ideas? I was thinking about cutting a small amount of the gasket out so it will fit inside the tank. I have been to every parts store in town and nobody sells just the gasket.

What my buddy did he couldnt find any tank gasket suppied, He just got some of those create a gasket sheets from the auto parts store made is own, Works like a charm, No leaks or fuel smells.

Good Luck.

Yes,

By all means you can make a gasket but it begs to be asked of all the things to purchase used, why a fuel pump, a known high problem item closely associated with age??

You may be switching out problem "A" for problem "B" with a fair amount of work. It may work for awhile but it won' be a long term fix.

For some things it is better to purchase them new but I guess if you are really strapped for cash and have more time than money, give it a shot!

Best of luck to you

Dave