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Alright, so your going to make it hard on us. I don't know the year of your car, in fact don't even know the model, but I'm going to assume that you've probably got a 700 series. You've checked the #1 fuse and said it gets a little warm. Do a double check and make sure your running a 25 amp fuse in there. Also, while your in there, check fuse #11 (auxiliary fuel pump) and fuse #13 (fuel injection system). Both those fuses should be 15 amp.
You said your main fuel pump is new but making noise. How loud is the noise? IOW, can you clearly hear it working underneath you as you sit in the car at an idle? The main pump should be silent with no noise at all. If your main pump is making noise even at a full tank then it's safe to rule out your pre-pump. With a full tank of fuel your main pump does not have to work nearly as hard to get the fuel to the engine. As your fuel level drops in the tank the main pump begins to work harder. To help relieve that stress you have in your tank a pre-pump. They both work hand-in-hand with eachother. However, you should not be hearing any noise from underneath the car, particularly with a full tank of gas. But since you have a new main fuel pump installed, in addition to a fairly new pre-pump, then the problem lies elsewhere . . . something is clearly putting a load on your main fuel pump (which contributes to your #1 fuse getting hot).
If your fuses are okay the only thing that I can think of, with the info. that I have, is that a fuel line is obstructed or your fuel injectors are not delivering fuel properly. That could be from clogged and/or faulty injectors or your electronic control unit (ECU) is not working properly. In relation to your ECU the 1st troubleshooting step to take is to ensure that ALL of the connections are solid and that ALL the wires are grounded to the spades attached to the inner fender of the front passenger side footwell. One loose ground or connection and a myriad of issues relating to your fuel system can arise. When looking at these connections physically take them off and clean with a wire brush (both the male and female ends). I'll leave you with that for now. Let me know if yo need the location of the ECU and the spades.
Good luck,
Nathaniel: VCOA
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