Here is a photo of 2 o-rings for the fuel pump.
The lighter one on top is from my 2005 donor or 2005 junk yard one.
The darker one on the bottom came with the brand new pump I bought online.
I spent 5+ hours yesterday trying to get the new o-ring to not leak when turning corners.
I had pulled the pump out 4 or 5 times trying.
Even doing the 1/4" allen key and drill bit, the gasket was still bulging in spots.
FINALLY I removed the pump
from fuel filter to see what was going on.
I grabbed one of the older o-ring to compare sizes and saw the difference.
I put the smaller one in and it wasn't almost up against the studs like the darker one on the fuel tank.
You can install it without removing the pump from the tank; just slip it over the lip and work it around.
Then I tightened it in a "wheel lug" pattern by sight to watch the gasket just start to compress.
NO MORE LEAKS!!!
Hopefully this post will eliminate someone else's frustration, just measure the green o-ring before installing.