Restricted fuel return circuit such as a pinched hose, partially plugged hose, internally collapsing hose.
Also, was the fuel tank vent checked?
First off i like your motto: "Quality repairs are the rule, not the exception!" Too bad that most people do not practice that. Unfortunately most business just want the money at all risks.
Now, The vent line was removed and found it was clear, reinstalled. Removed return line at the secondary and blew air thru it, it was free. There are no rubber lines on the return line. I turn on key , engine cold, and the electric pump is pumping fuel back into tank and can hear it flowing back. This procedure was done BEFORE i started the engine after sitting for a while. It sounds like the return line terminates at the top of the tank fitting because it makes a lot of noise in the tank.
So here is the summary of return line tests.
1) with engine cold the return line is free and fuel pours back into the tank.
2) after the engine dies i leave the key on and listen for fuel return back to the tanks and there is none.
One thing i did to test the fuel flow was after the engine died and i left the key on so pump would keep going, i cracked open the supply line INTO the pump (at the rear) and there was plenty of fuel flowing out. However when i cracked open the line OUT at the CV I had no fuel coming out. I then tightened the lines back and listened for fuel return to the tank and there was none.
Any ideas? i would hate to install a new pump and get the same results because i missed a minor item. LOL