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I have just put a rebuild kit through my oil pump on my ute (3 days ago) and it is leaking again already! (Where the gasket goes between the block and pump) Does any one have any suggestion of what could be causing it? I Cleaned everything thoroughly using degreaser and White spirits; also i used silicone sealant on both surfaces and Subaru gaskets (Black Maxx off memory). All bolts are nice and tight. I am open to ideas? I am about to make sure the bolts aren't bottoming out in the block.

Cheers
Matt

Are you sure the pump housing is not cracked.
I had a similar problem a few years back with my 82 wagon.
It had a small crack in the housing so I went to the local wrecker and they pulled 3 off various cars and only the 3rd one did not crack when it was removed, the other 2 cracked.

Did you just remove the pump, clean and replace the seal? If so, there's a section of the pump that oil can still leak from - when you take the pump off there's two screws on the face of the pump that mates to the motor, this effectively dismantles the pump. If you haven't opened this section up and sealed it when you took the pump out I bet this is where the leak is - The same thing got me with Sunnie and I'm yet to pull it off and fix the problem, its been almost a year now...

Cheers

Bennie

Replaced all the Oring's and gasket (Read about 4 Orings i think and the gasket). And there was no crack that i could see and i know where you mean as the first pump i cracked years ago.

I have exactly this problem with my Brumby. I've replaced all the o-rings and gasket in the oil pump and it is still leaking, apparently from the join with the replacement gasket. I'm wondering if the pump housing is be warped? Does anyone have anything further on this? Matt: did you find a solution to your problem?

As an offside with EA81 oil pumps - how reliable are these things? Should they be replaced at a certain age even if perceived to be working properly?

The housing can sometimes have some casting that gets in the way on reinstall which is what happened to mine and do not know how it will ever come out again. Should not have neaded the resounding thump with a rabber mallet but did the trick getting it back in. There are specs in the manuals to assist. A good clean with solvents and cast a god look over it. Some settings via springs and balls not to be touched after factory i think.
Many hundreds of thousands of trouble free pumping if they keep getting clean filtered oil, not hot, no crud in them.

The pumps are bullet proof, the oil seals go like every 50/100k km.

onethousandhp: Mine tuned out to be one of the orings not seated correctly thus leaking. Replaced the oring and i was good to go!