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2G Full Blown Fuel Hanger Fumes

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Yamahaulin

10+ Year Contributor
695
12
Jan 30, 2010
Bowling Green, Kentucky
I have the full blown dual pump hanger and it is starting to get worse on the fumes getting into the car. Anyone got any ideas how I can make this better? I constantly leave my sunroof open so they can escape, and as one would think it's worse on a full tank than with less. I have read before that it is cause by how they seal the wires that got through the top of the billet piece. Hopefully someone has something that can help me out as winter is coming and will be too cold to be leaving the sunroof open.
 
Did you put in a new gasket? I have no idea how those things work because I run a stock setup and don't really see the need for such an expensive piece of hardware. They look to be a drop in piece however and the OEM gasket is usually junk and needs replaced.
 
Gasket was in good shape when i replaced the hanger. I could try a new one but i don't believe that's where the problem lies.
 
Have you checked...or thought about the hoses? I know that the braided tend to let vapors through. I wonder if they start to let more vapors pass over time? Just a thought.
 
I've checked hoses and they seem great. I use Russell pro classic it's not a braided stainless. Hose was installed brand new 2 years ago but car has only really been up and running for the last few months.
 
Couldn't you just seal up the access cover so they don't cone in?
 
If it's a known problem, I would try to seal it with some fuel resistant urethane or silicone or what not. I'm not sure about compatibility but 3m window weld is awesome, read the back at an auto parts store and see. Or some black permatex rtv.
 
It is very possibly the braided lines. IDK what composition Russell pro-flex is, but if the tube part is rubber and not Teflon, vapors will permeate. I smell my non-PTFE hose outside and it smells of fuel. Smelled my Teflon lines, no such scent. This is a pretty big argument on both sides. I am not the only one on my side.
 
Those are good fuel lines. Should not have any fumes from them. Years ago I did my whole fuel system with the rubber lined braided SS lines and the car smelled like one big fuel leak on wheels :(

Have you checked the grommets where the power wires go through into the tank? Just trying to think of anything else.
 
I've been trying to contact Full Blown for some information but no response. I really don't care for this company's customer service as I have had issues getting info from them before. I think where the power wires go through to the tank is the problem. They sealed them up with some kind of silicone or epoxy that I have read before that the fumes breaks it down causing this fume smell. I would love to seal it off but I had to trim the body of the car to clear the output lines so there is a small gap that isn't covered by the little access door. I may purchase new rubber gaskets and then try to apply some more sealant to the power wires.
 
Replace the seal that seals the hanger with the tank. I recently installed a full blown hanger also and "thought" my gasket was good. Turned out it wasn't.
And when the car wasn't up and running did it sit outside? Even good Russell lines will dry rot when sitting to long, allowing fumes to escape
 
The car sit for 2 years half outside half inside.
 
I think it might be the gasket, or like you said the power wires. When i put my wally in i snapped a few bolts and it stanked up my whole car. Two years isn´t that long for those nice russell hoses to be leaking ethanol or not. But i guess its possible, i hope its not the lines for your sake.
 
I don't believe it to be the lines as i can't smell any gasoline at the fuel rail. I'm gonna replace the gasket and try to add something around the power wires to see if that will cure the problem. Because the very first day i installed this and the lines 2 years ago the first time i put gas in it i thought it was leaking fuel cause i could smell it.
 
I would suspect the gasket.....only because I was replacing my pump a few years back and got a brand new genuine Mitsu gasket because I wanted to be sure there would be no problems. When I went to install it, it just didn't fit correctly. It kept getting lumpy and out of place when i went to put the pump hangar back in. I gave up and put back the original one.
 
Please make sure that every thread on this pump has thread sealer or it will leak slowly but surely till you find the top of the unit saturated with gasoline in spite of having a new gasket ring installed. Problem is not the ring in most cases it is the fittings. Solved when I put thread sealer on every single last fitting that came with this kit.
SUCKS it never came with instructions. Also on the AWD 2g has to be put in at an angle or the Siphon hits the baffle making it tough to go in.
 
If I ever do end up using my 2g Full Blown hanger, which I doubt I ever will, my plan would be to machine it out and use some rendition of this harness for the electrical penetration:

https://www.ebay.com/itm/Radium-Bul...l-Triple-Walbro-F9000262-17-0028/201605532434

The 2part around the wires is a guaranteed eventual fume leak, which is not acceptable. I got this idea from another thread, I believe it was here on Tuners.

Wiring info from Full Blown is available but they generalize even though the part is vehicle specific, most likely to just stay out of that part and keep things simple for themselves. But they do give you enough to figure it out.
 
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If I ever do end up using my 2g Full Blown hanger, which I doubt I ever will, my plan would be to machine it out and use some rendition of this harness for the electrical penetration:

https://www.ebay.com/itm/Radium-Bul...l-Triple-Walbro-F9000262-17-0028/201605532434

The 2part around the wires is a guaranteed eventual fume leak, which is not acceptable. I got this idea from another thread, I believe it was here on Tuners.

Wiring info from Full Blown is available but they generalize even though the part is vehicle specific, most likely to just stay out of that part and keep things simple for themselves. But they do give you enough to figure it out.
Thanks for that link. I just added it to my cart and will consider doing the same thing if I eventually smell gas fumes. I saw the link you are talking about called "modified fullblown dual pupmer" or something like that where the guy uses the same kind of plug set up.
Right now she is leaking fuel from the copper 90 degree fuel fitting they provided me with and I have to seal those threads.
Again thank you for the link.
 
I have the 2G AWD version. When I first put it in and got it tuned I would get a nice mist of e85 every time I'd come off hard throttle, and I could smell gas strongly when sitting in the car.

I added E85 compatible thread sealer to the fittings going into the hanger assembly (not the AN fittings), then used soapy water as a lubricant on the rubber o-ring that seals the tank when tightening the lock ring (soapy water was specified in the factory service manual). I used a torque wrench and the lock ring tool and torqued it to spec. never had a problem since.

I did notice while storing my DSM for winter this season that the silicone that FB used for the wires is actually cracking a little on the inside and I still don't smell anything. I had the whole assembly out to pickle the pump on gas. The pic is obviously not how I run the car all the time, I'm just showing where I put the sealer.
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I see you had to install the pump turned a little also. The thing was kind of a pain in the ass to put in because the darn siphon kept hitting the baffle.

Definitely not going straight in like the stock pump setup but the guy who designed the pump never tells us nor gives instructions. :rolleyes::ohdamn:

I certainly have to thread seal that gold fitting you have there as well. Mines leaks.I used thread sealer on the AN fittings as before those were leaking as well but stopped after I sealed the threads.
 
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yea, there is a whole service bulletin about clocking the OE pump assembly properly for the gas gauge to function accurately. There is no clocking this thing haha. One way and one way only. I have a single 450lph on it tho, I wondered if it would be different with (2) 320's. What pump/s do you have on yours?
 
Thanks for that link. I just added it to my cart and will consider doing the same thing if I eventually smell gas fumes. I saw the link you are talking about called "modified fullblown dual pupmer" or something like that where the guy uses the same kind of plug set up.
Right now she is leaking fuel from the copper 90 degree fuel fitting they provided me with and I have to seal those threads.
Again thank you for the link.

Been in my cart for like a year, every purchase I make I click save for later haha. Hopefully you never need the harness, but at least its there if you do, and the quality is 2nd to none.

I think I read somewhere about trimming the baffle for better fitment............or that might be totally wrong, sorry, its been a while. That might be a horrible idea even, just passing along what I (dont?) remember from exploring this option.
 
I know there is a really good write up on doing a whole bunch of work to this product somewhere on here. I saw it the other day. Additional machine work, a MIL-spec bulkhead connector for the wiring, and some other mods. May be worth looking for.
 
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