Hey Pyro. Not sure about TBI fuel pressure as I have the MPFI and don't have my book right in front of me but yeah, I thought the pressure was considerably higher as well.

On the MPFI 2.6 the pressure is supposed to be at 35 psi with vac hose on pressure regulator connected and 40 with it disconnected. Sorry I don't have my bible here to check your TBI pressure.

As far as corrosion at the fuel pump harness....got time...grab and beer and I could tell you stories. After dropping the tank several times in a two year period due to corrosion at one point or another in that assembly, I decided to straight wire it and I use several coats and I do mean several...like seven....of "liquid electrical tape" at all connections. The stuff smells real bad, can get you high in a hurry but will protect your connections very well. I live in the North Country where we have long winters full of road salt and I just couldn't stand losing the battle any more.

As far as something electrical heating up to the point where it fails...that's a possibility. Which component, I couldn't tell you but those things all work with some kind of resistance or other whether it's some kind of thin metal strip that bends to close a ciruit or stretch to open a circuit, or maybe mercury controlled, the heat plays the roll in either opening or closing that circuit. If something is getting too hot, it may shut down and then when cooled, it's fine again. Wish I knew more to help you and hope I haven't mis-spoke on what I think I know....

good luck...