I will fly in and out of Barcelona and will rent a car after a few days in the city.
The plan is to stay 3 nights in each of Barcelona, Pyrenees (Tena Valley), Pamplona (alternative is Bayonne France), Bilbao, Burgos, and then back to Barcelona for departure.
- should I hike Montserrat on the way to the Pyrenees? After I pick up the car and drive there, it may be closer to noon and may get hot, plus I heard it tends to get busy. It looks sweet though. 
- are towns in the Tena Valley (Biescas, Escarrila, etc.) good bases for day hikes, relaxing and scenery, or would you recommend places like Jaca? 
- I plan to cross the Pyrenees and come back to Pamplona from the French side, touring St Jean Piere de Port. Is 3 days too much for Pamplona? I can do some side trips around Pamplona and relax. Alternatively, can stay in Bayonne and tour French Basque country. 
- Burgos and Pamplona seems less popular in summer as everyone heads for the coast. Are they too hot to be enjoyable without AC? I checked their climate, seems their night time temp is quite comfortable so I should be fine? 
- I'm staying in Bilbao and Pamplona because accomodations are hard to get in SJ de Luz and Donostia is expensive. I'm also not a huge fan of beaches.