Quote Originally Posted by DMCMW Dave View Post
Check the other fittings, i.e. the rollover valve. I've seen the factory install of the upper cover crush the vent hose, which will cause the tank to pressurize.
This is an interesting theory. Immediately after the initial installation of the pump I went out for a fairly long test run (45 minutes or so) and I don't recall smelling gas. If I did, it was slight and I'd probably assumed it to be the result of having been screwing around the tank for half a day.

The interesting part is, I went for said drive with the fuel pump access cover not installed. (I assume this is what you were referring to by "upper cover"?)

Also, what's the best way to get at the fittings for the rollover valve? I have to wonder if any of these other things are the case since I didn't have this problem until after I replaced the fuel pump.

Quote Originally Posted by DMCMW Dave View Post
The pressure has to go somewhere so it either burps out the fill cap, sender, etc wherever it can get out. Make sure someone has not capped off the hose to the carbon cannister - same problem. The delay you see implies to me that the tank is pressurizing or trying to.
I do think it's a pressure issue of some kind, because everything you said here makes sense. When I got home and checked the fill cap, I pulled it off and the fill tube "coughed" at me, expelling some vapor. I guess it's just a matter of figuring out where/why the system is building pressure.