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Discussion Starter #1
My old Zuk Sami ('87) fuel pump quit and I replaced it, but it has leaked at the gasket despite resealing it a couple of times when it should have easily have been sealed tight.

I'm talking ounces of oil, and not a few drops, either, and it runs down leaving a puddle under the car after shutdown. The old pump never leaked a single drop. I put dye in the oil and looked with a black light and found the stream coming down from the pump, and dripping off the bell housing (I originally feared a bad rear main seal).

I just re-pulled the new pump and it looks fine-no cracks in the casting or anything. Gasket looks like new.

I have another new one ready to go on, but wonder if there is a return oil passage for what oil runs down the pump activation rod that could be clogged that is building pressure behind the pump. I really don't see why the new one wouldn't leak like the last new one has been.

The engine only has a few hundred miles since a rebuild a few years back, and it is sludge/deposit free.

Anyone experience such a leak ever?
 

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Discussion Starter #3
Think I found the problem-

What on previous removal appeared to be a shallow casting flaw is likely a through-crack.

Filling the lower cavity w/ brake cleaner caused dripping.

Cold oil- no leak.
Hot oil, leak.

Click to enlarge photo to see horizontal flaw/crack.

 
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