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More digging reveals the pump is supplying more air than fuel, must have a leak on the intake side, despite checking everything/renewing all seals there.
I eliminated all possible air leaks on the suction side, fed the pump from a jug of clean fuel to eliminate the in-tank pickup as well, and still got air from the outlet.
I called Burlen this morning, and they told me that some internal seals/gaskets on pumps more than two years old have proven to fail due to the ethanol content of modern fuel, and one of the symptoms is sucking in and pumping air. So I have an overhaul kit on its way (which has ethanol-proof seals) and will report back once that is fitted.
The scary bit is that this means that many of us may have this problem in time........................
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