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Dear WrenWright,
Hope you're well. I just did one of these and had trouble re-installing the send unit into the tank.
What Chris Mullet highlights is correct. The steel bracket - that holds the "buffer unit" (black plastic with metal twin-cap) tight to the pump's output nipple - has not been installed correctly. The steel bracket's arm is supposed to fit squarely in the slot, on the left side of the photo. One side of the bracket's arm is not in the slot. It is wedged between the white plastic pump base and the wall of the pump.
Further, because the bracket is not seated squarely in the slot, the "finger" at the bottom of the white plastic base cannot snap into a recess in the bracket's arm. As a result, the pump is not locked to the buffer unit. Instead, pumped fuel has pushed the "buffer" unit upwards, so that fuel is not entering the buffer unit. Rather, the fuel is pouring from the pump's output nipple, back into the tank.
The car started the first time, likely because the fuel pump's output nipple was partly into the buffer unit. The force of the pumped fuel pushed the buffer unit upward (and the pump itself downward), until the nipple came out of the buffer unit. As a result, no fuel entered the hose and so soon as the engine had used the fuel in the line, the engine died and would not re-start.
If the bracket is installed squarely into the slot in the white plastic base, the bracket will lock the buffer unit to the top of the pump, and the pumped fuel will go into the hose, and thence to the engine.
Hope this helps.
Yours faithfully,
Spook
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