Need a bit of help. I have a freind that has a '92 240 no turbo. Some time back it quit running, he thought it was out of fuel, tried that, etc., etc., and then finally called me. I went to his house, and found the fuse to the fuel pump was bad. Replaced the fuse, good to go. Then, it started blowing these fuses randomly. Might blow 2 in one day, or go 2 weeks before it blows one. Has had it to a local garage for 4 WEEKS, and the guy says he hasn't a clue what's wrong. Says the fuel pump "checks out" OK, etc., Any ideas? I figure it is either a bad connection, or something is drawing more amps that it's supposed to. But, I didn't think that those fuel pumps usually went bad like that. The dealings I've had in the past were: it pumped or it didn't.
Any ideas?

Did you ever figure this out. My 93 240 is doing the same thing. It will randomly blow the number 6 fuse. Usually at high speed over bumpy road so I think there is a short somewhere.

My 89 240GLT had a similar problem. The pump and wiring were quite tired. Uprated the fuse. Bad idea, burnt out the fuel pump relay, which is expensive. It's not just an ordinary relay. It's a safety device that only pumps fuel if the engine is turning.

The fuel pump was drawing about 16 amps, twice what it should I believe. I got round the problem by putting a 40amp relay under the back seat, directly above the pump, and running a new 40amp wire (new wiring is fairly thin and flexible) from the battery to the new realay. The original wiring (via the fuel pump relay, now only carries a low current signal to the 40amp relay.

Of course, the real solution is to replace the pump(s, but in the meantime, I'm not destroying expensive fuel pump relays.

brian

Might also wanna check the Fuel Pump Relay, too. it's white and under the glove box

i WOULD THINK MOST LIKELY THAT A WIRE IS SHORTING OUT SOMEWHERE.
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!965 NSU Prinz,1958&9 VW Beetles,1972 Renault R10,1970 Fiat 850,1972 Chevy Nova,straight 6 3 spd.topped out at115mph,1982 VW Rabbit,1987 Ford Econoline Straight 6 Supervan,445,472 miles before it flamed up!1989 Ford Taurus Wagon 3.0V6,took 18"of snow to s

Kinda what I thought too. Thanks!

My sister's '92 240 is having the very same problem. Both fuel pumps are less than two years old, and the fuel relay is the same age. The ECU is also two years old, so I am rather confident that the problems rests elsewhere. Please let me know if you are able to figure it out. Have a splendid week one and all :)