Bora, is there a way to inspect the HPFP for signs of excessive wear to prevent this?
Not really, there's the old "are there metal shavings in the fuel filter?" However, generally they let go before it's noticed.
My line of reasoning is thus:
1) How much does it cost to replace the whole system?
2) It's lasted 150,000 miles, do you expect it to go 300k? Get it changed before it goes catastrophic. The newer generation pumps seem to be performing a lot better too.
3) I originally studied to be a commercial pilot - A 737 pilot for Southwest once told me that "maintenance is the interruption of what will be an inevitable failure."
In the corporate world a part has a designed lifespan. Most VE pumps last on average 150,000 miles. PD injectors are about 200,000 miles. I've put an average lifespan of a HPFP at about 150,000 miles based on what I see every day. Some will last longer, some less, but at that point it's better to replace than wait for that inevitable failure to happen. Costs are a lot less too! As of this writing a VE pump runs $950-1100, PD injectors are $1500-1600/set, and HPFP's only run $500...
Good idea to have the 1 micron fuel filter kit too...
My '10 still has the original pump in it - but it only has 29k on it, and it has the extra fuel filter.
-BB