Update on pump re-install
I'm updating this thread just in case anyone needs a reference in the future:
Just about 2 months later, the fuel pump is back in the Bimini Twist. It's a full day to remove and a full day to replace; it's really not too difficult a job but getting everything lined up just right takes quite a bit of patience. The reason it took me so long from start to finish is that I'm about an hour and a half from the boat and it seems like I've been to a wedding every other weekend this summer.
After removing the pump, we took it down to PCE (Propulsion Controls Eng) in San Diego. It took them about a week for the rebuild. From what I was told, there are high pressure control valves in the pump and one of them had failed. As a result of the uncontrolled high pressure the gaskets in the pump housing had blown out, causing the leak. I'm hoping that the high pressure was also a factor in the rather poor fuel mileage we were getting (<2 mpg). Final price tag from PCE was around $850 including parts, plus tax.
I took some photos along the way but I'm not sure how comprehensive they are. I can try and put together a photo tutorial if anyone thinks it would be helpful but I'm also willing to walk someone through the project in person, too.
There's a trick or two that can save some time (and frustration) during re-installation but it's pretty easy to trial-and-error your way through the process. As long as you get the timing right, there's really only one way that all the pieces will fit back together. The engine runs fine with the new pump but now I'm having some problems seating the strainer so that it's leak free. I'm using RTV Gasket Material to seal any gaps, however, I haven't been able to get the engine side to stop dripping.
I need to say thanks again to Peter, former owner of the Longfin, for letting me borrow the pump timing tool, TDC lock, and manual even after he sold his boat.
I need to get the raw water pump going and then we'll see you in the water.