Alright calm down. Nice of you to reply but no need for the attitude. More pressure => more resistance => heat. We see it all the time - in electrical circuits, friction systems such as brakes, clutch, gas flow etc, ever pumped up a tyre? So it's a perfectly reasonable question and no harm in getting a second opinion. The pump isn't tight - won't freewheel but not tight. I see no reason why the new pump doesn't align but the old pump was okay.
oilhead - the cap is a nut that holds the solenoid to the valve that it controls. I have felt the old pump before it became defective and it didn't get hot at all. Nor did the pump on my friends burner. I won't be changing the boiler in a few months as the council have put planning applications on hold and I'll have to endure another winter at least before building starts.
John - You can get a firm grip on it for about 3 seconds before it gets to hot to hold. I suppose I'll just get the pressure adjusted and let it run for a day or two and if it fails it fails. At least if that happens I'll have time to sort out something before the really cold weather kicks in. Motor doesn't feel hot.
Anyway I can sense some you are getting fed up with this thread so maybe best to call it a day on this one. Thanks all for your responses. Much appreciated.