97 SC Cobra

I put this kit in last summer and it has leaked from day 1. Just getting around to trying to fix it today but have a couple questions. Car is a 2002 Z06. It looked as though the fuel was leaking at the bottom of the bulkhead at the 5 o'clock position if facing the bulkhead with the system installed in the car. When the assembly was pulled out of the tank and bulkhead separated from the factory gasket it looked as though the factory gasket (where it flattens out) is almost too thin to bridge the two o-rings on the back of the bulkhead. Pic here:
I just don't see how this can make a good seal. It's leaking at the narrow part on the factory gasket where it meets the orings. Just wondering if installed this wrong or maybe even have the wrong kit for my car?
Emailed Doug, waiting to hear back but it's bugging me so I thought I would ask here as well.
Thanks guys🍻

Smoken1

Looking at your picture it looks like your double gasketing. Looking at my fuel ring it came with 4 O-rings so take the factory one out

97 SC Cobra

Thanks for the reply smoken. I thought about that as well but there are little raised studs if you will where each of those long m5 screws land. I'm not sure the o rings in the bulkhead would make contact with the tank otherwise. And there's this part in the instructions where it says to leave the factory gasket installed.

Smoken1

Which ring do you have?

97 SC Cobra

That's a great question! I'll go outside and check in a few min. Thanks for that pic! Definitely going to shed some light on the situation.

97 SC Cobra

I have the 3.75" block which looks to be correct for my year. I kinda wish that was the problem lol. Would have been an ez fix. This is my tank, not sure if every year looks like this but anyway.

Thanks for the help.

Smoken1

My 02 vert has those also maybe Doug will chime in and help out. My fuel ring goes in as soon as it warms up outside...

DOUG @ ECS

It looks like you are double o-ring'ing it. The tank side gets the original gasket and the sending unit gets our o-ring seal.

I think that is your issue from looking at the pics you posted.

Turpid porpoise

The first picture appears to be the OEM gasket on the tank side of the ring but it looks worn to me. Have you tried replacing the OEM gasket? I personally had to massage one of the pipes in the fuel hat to keep the bucket from hitting the bottom of the tank. Until I straightened the pipe out a bit I couldn't get my fuel hat to sit flush, maybe this could be your problem as well.

97 SC Cobra

Thanks for chiming in doug and purpoise 🍻. Yes it is definitely is double gasketted. Guess I figured I had them to put in and there were grooves there so I did it? I would have a had a couple left over if I didn't. Why even cut those grooves in the bulkhead if there's no orings there? The factory gasket doesn't look like it lines up to fit in them? Sorry if my questions seem ridiculous guys. Thanks for the help. And yes purpoise I had to bend mine as well, maybe I will try a bit more this time.

Smoken1

OK just looked at mine the grooves in the fuel ring seem to line up with the OEM gasket

Smoken1

I'm guessing they send a 2nd set of O-rings for future use

97 SC Cobra

I'll have to check and see if they line up. Looking at it I don't see how that's possible being the gasket tapers in 2 spots. The grooves are not concentric the whole way around and the bulkhead grooves definitely are. I see from your pic that it doesn't really matter that they line up though. I guess the inner ring does fit despite what the outer is doing. Still looks like it would seal. Thanks smoken

Smoken1

Let me know if it all works out if you get to it b/4 I do
I have an extra new gasket if you can't find one local to you

97 SC Cobra

Thanks brother I appreciate the offer. I don't want to put you out. I'm going to grab one at the dealer as I want to tackle this on the weekend. 🍻

97 SC Cobra

Just wanted to post an update as I replaced the factory gasket and reinstalled the pump correctly (without the O-rings on the inside as well) Everything is as it should be, no leaks.
Thanks to all who responded

JD White

I'm in the middle of installing this stage 1 fuel kit right now on my '02Z and think I'm running into the same problem you had. With the ECS ring in place the hat simply won't fully twist into position to sit flush and install properly. Do you recall which pipe you had to adjust and how you adjusted it to get it to fit?

ECS is usually great but it's really pissing me off that this doesn't fit into place. If they know about this, it should be mentioned in the instructions.

Smoken1

I had to call ECS about this problem. You have to bend both pipes up a little to get it to fit

JD White

Thanks for the quick response. I'm hoping you didn't need to dry it out and heat it up to do so?

Smoken1

No heat needed, just put the hat in a vise and bend the tubes. About 1/4in it should turn into place