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Fuse holder #6 melting 200 1991

Fuse holder # 6 in a 91' 240 is the fuel pump only, there are three wires on it. The "hot" side (or unprotected side) has got so hot it has blackened and melted the plastic (nylon?) plate. The contact moved apart so the fuse is loosly held. The result is intermittant stalling or failure to start. I squeeze the fuse holder contacts togther restart, and go on my way.

On the "hot" side is a heavy gauge (#10?) red wire coming from the power distribution block on the driver side fender. Also on that same side is a light gauge (#16?) red wire. This light gauge wire diffinetly looks like it has seen too much current. The insulation is sagging, you can see the strands of wire through the insulation.

On the "protected" side a light gauge red wire goes to the fuel main relay, this one is not melted. Where does the light gauge wire go. (the one thats on the same side as the feed and therefore "unprotected")

I have the Volvo shop manual from the dealer, it shows several dotted lines where some optional feeds go on the "protected" side but nothing other than the feed on the "hot" side.

I guess I could just unplug it and see what doesn't work.

Thanks, Steve M.








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    Re: Fuse holder #6 melting 200 1979

    Same fuse story with me, too. Plagued me for 15 years!

    I finally replaced my entire fuse holder assembly w/a brand new one. Problem solved... although cleaning the points like the others suggested sounds good also, but the part is cheap; about $35.








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    Re: Fuse holder #6 melting 200 1991

    Steve -- about 18 months ago I was having a similar problem with the fuel pump fuse holder on my '81 245. I checked the amp draw of the fuel pump and it was right in spec. I was told by several posters that where the resistance was highest (i.e., the fuse holder) is where the problem lay. So...I went to my local pick-n-pull and snagged two good looking fuse panels. I took the cleaner one and cleaned it some more, pinched the clips tight and replaced my melted one. I haven't had a problem with warm fuses or wires ever since.

    Rob








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      Re: Fuse holder #6 melting 200 1983

      Steve - I, too, had a similar experience as Rob with my '83 245 GLT. You wouldn't imagine the places that car chose to stop with my wife or I for a few years. I carried several spare fuses, taped them to the fuse block cover with directions to my wife on where to put them in case of this problem. It was getting as frequent as a couple times a week. Smoked wires sometimes, too. When the mother-in-law weighed in this problem, I couldn't take the "heat" any more and so I sought professional assistance. Fixed it by cleaning the fuse block contacts - and I'm worry free.

      Here's a stranger twist. Shortly after the fix, the car begins to run rough and then a guy pulls up along side me on my way to work one dark morning. Tells me my brake lights don't work. I ask myself, both? Hmm, fuse? Well, it was a wet and rainy day. That evening, I finally take time to check fuses, pull off the cover and with a flashlight begin to inspect fuses. Then I notice all these water drops near the bottom!! Sop up the moisture, no blown fuses, start back on my way, lookin' good now. Then it comes to me. A few years back I had the windshield replaced. They never really got the gasket ends to mate up on the driver side, so I had a gap. Moisture had been leaking through the gap and down to the fuse block, corroding connections! Patched up the gap with electrical tape and I have yet to experience another episode.

      Listen to Rob.

      Michael ('83 245 GLT, '83 240 DL, '92 240 DL, '90 760 GLT)








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    Re: Fuse holder #6 melting 200 1991

    the real problem may be excessive current draw from the fuel pump.

    They draw 2-3 times as much current as they get old and prior to failure.

    Or so I've heard.........








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      Re: Fuse holder #6 melting 200 1991

      John,

      Shouldn't this cause the 16Amp fuse to go? Or is the Fuel pump feed that wire on the "Hot" side? When I pull out the fuse, I don't hear the pump anymore.

      Steve M.








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        Re: Fuse holder #6 melting 200 1991

        it sounds more like high resistance where the fuse/or wire connects with the metal housing. check the wire connections for corrosion. (do you have plug in fuses or the open barrel type?







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