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ThIs has turned out to be one issue after another on this car. I’ve got a Brand new Delphi fuel pump and brand new delco sending unit, and I’ve run into a snag trying to get the two together. The hard plastic line of the pump seems way too tight for the sending unit. Has anyone had similar issues? Each piece looks identical to the one I pulled out of the of the tank but I cannot get this line to fit on the sending unit. I am by no means a small dude, so I feel like I’m forcing enough pressure on the line to slide it onto the sending unit, but as you can see from the pics I’m not even close. I’ve even tried to lube each end hoping it’ll slide over but still gave around 1/4” to go and I’m at a loss at this point. Any thoughts? Send them both back and buy the complete pump and sending unit from spectra? Would it be a bad idea to cut off some of the line on the sending unit?
I think it can be done either way in theory with the clip on the receiving end or pump end. I tried it both ways and neither worked. It seems where the hard plastic line on the pump tapers down (where the o rings are contained) is just way too tight for the line on the sending unit.
Sorry for the crappy pics, hopefully the lines are visible enough to compare. Took some with the clips on and off to give you a better idea of how they look. I also noticed the new one doesn’t have the retainer bracket on the sending unit for what I assume is a vent line out of the pump housing? Is it possible this is the wrong sending unit? Did later models not have that hose?
Can you get a caliper and mic the diameter of both ends, then use the depth gauge to measure the length from the crimp to the end? That will tell you if the something is not right size wise. They look close.
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More fuel pump issues 
