Overheating fuel pump 86 XJ6
 

You may consider this a continuation of the thread Thick Black Smoky Exhaust then back to normal.

I installed a new Bosch fuel pressure regulator and Bosch fuel pump (69414), which cured the engine stumble but now the new fuel pump is running noisily and very hot some of the time. By hot I mean I'm afraid it will melt plastic things around it, or maybe start a fire on a long run.

I think my only remaining fuel delivery problem is the non-functioning cold start injector. Have any of you seen this overheating fuel pump issue before?

My car has the single inline pump located in the trunk. Thanks for any ideas!

Noisy fuel injection pumps are either going bad or being starved for fuel. IF the pump is good another source of noise is cavitation. The fact that the pump is hot seems to suggest that it's not moving enough fuel to cool it. I'd look for a restriction on the suction side of the pump.

I believe you're on to it...the pump is fine when I use the left-hand tank.

And to wrap up....I feel très stupide for trusting the fuel level sending units. The pump was indeed starved of fuel cuz the tanks were empty while the gauge indicated 3/16 either side. Having learned that, I am no longer punishing my car by running it out of fuel.