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"can feel squish of fuel in the return hose on the back of the FPReg with 4 and 6 jumped and also if I push the valve on the rail there is a puff of fuel/air coming out"
The "puff" part has me concerned. Sounds very certain you feel air or fuel vapor escaping when you invoke Mr. Shrader's relief. That should not be. Only liquid should be in that rail. However your note that plugs are wet when this happens doesn't jibe with vapor lock.
And the squish test I suggested last go'round doesn't really eliminate a regulator that occasionally sticks open. What threads are ruined? Those on the rail fitting or on your gauge adapter? I hope the latter. There's a recent post on TB (I'd link if the site was up) describing an eight-dollar adapter kit for the Bosch LH 14mm Volvo fuel fittings available from one of the tool companies.
My question, which you've probably answered (so please forgive my lack of research) is whether you've replaced the regulator with a Bosch. I say "with a Bosch" because I've read that others exist and they get trashed in the forums.
Also you say "both pumps are operating or at least sound to be - jumped fuse 4 to 6 just to make sure with no luck" and I find myself still wondering if you know both pumps are operating. Yes, I know you've said you have a new tank pump, but I know new does not equal working. When testing separately, do you hear them both? Is the main pump running with a smooth hum?
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Art Benstein near Baltimore
"Do not machine wash or tumble dry" means I will never wash this ever.
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