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I finally decided that enough was enough and started tackling this issue. I tried working through a dealer, but that was an epic failure.
As a starting point, yes, I had a DW 65cc pump installed in combination with a JRSC, flex fuel kit and 700cc injectors to handle E85 duty.
After exposing the pump there certainly appeared to be a lot of fuel residue around the pump / lock ring area. There is a slight slope in the pump area towards the front of the tank, which could explain that if there is leaking through the pump seal / lock ring, why it would flow down in front of the driver's side rear wheel (that's the direction of the slope in the top of the tank, and the pump is located just in front of that wheel).
After a visual inspection, I couldn't find any evidence of leaks on the fuel or evap hoses and connections in the area, so the evidence suggested a pump seal issue. I removed the ring and pump canister. The gasket around the top of the canister had a very thin lip, flange, flap in the middle that looked like it had been folded over or "squished" unevenly, as well as partially torn away from the gasket. While its possible that I did that when removing the canister, I don't think so since I tried to be careful and certainly didn't "rip" the unit out of the tank.
Thanks to other members and DIY threads, I was able to get a part number for the gasket. The gasket is advertised as a "must replace" part with servicing. I do not think my was replaced with the DW pump install. Perhaps that flange is so weak that one installation (at the factory) is all that it can handle.
After confirming that the part was not on hand within 50 miles (including World PAC and other suppliers) I ordered 2 (just in case) for a new install, along with a pump ring tool for hopefully precise tightening.
The diagram above and guidance on using a silicone sealant is very helpful, thank you.
Two questions: 1) can I simply install the gasket on the canister, seat the canister in the tank and screw down the ring? 2) what brand / type of sealant? Silicone comes in all shapes and sizes.
Thanks guys,
Aaron
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