[Gordo2]

I'll hit these in order:

Yes, I checked the tank (through the fuel level sender) when I found the return was plugged - I was happily surprised to find it clean as a whistle for the most part, but it did have some rusty surface residue around the return assembly.

I'm running a Walbro GCL604 - which has specs/performance close to the original Bosch CIS pump:
- Operating Pressure: 73 PSI
- Minimum Flow @ Outlet: 56 GPH High Pressure

How big of a deal is 5 PSI vs. the preferred 3.5 PSI?

Gordo