Had to leave work early as when I went to fill the Z tank, gas started pouring out past the sender oring
I assumed I had not seated it correctly, which seemed hard to fathom, but it must have rolled when I was tightening the lock plate.
I got home after losing prolly 3 gallons or more - the needle had dropped from around 2/3 to under half after the 20 min drive. I was praying I didn't pass anyone smoking with an open window - I'm pretty sure there was a fuel mist in my wake.
I drained about 4 gallons to get the level below the sender. Couldn't see anything wrong with the o- ring, but I reinstalled with the original as it appeared & felt to be a thicker wall.
Adapted the harness
Put the gas back in, and the big leak was gone, however the new sender (off AliExpress) was leaking around the ground pin. Now I was wishing I hadn't mutilated the original sender when I cut the wires off. When I did that I yanked on the gauge terminal and it pulled out of the sender.
So now I had to fix the original sender just so I could put it back in until I get a new replacement quality unit.
I riveted a Volvo coil terminal connector using the original nylon spacer and the inner seal seat for the gauge terminal. Installed, no more leaks
That done, I wanted to take care of the appearance at the tank and the rear valance as they both looked kind of s*****, and I'm going to the Carlisle Import Show in the AM .
So I sprayed the tank with 3M chip protection, then after an hour and a half, the 3M undercoat. Metal splash guard sprayed separately, and installed after I took this pic.