Your problem is very typical of later model 240's. Apparently, some Volvo engineer was not paying attention as more and more stuff got added to that particular fuse spot! The a/c, optional fan, and window lifts are too much for that little 8 amp fuse. My mechanic made a suggestion that has worked, though I am not entirely comfortable with it. The only reason I would even try it is because this guy worked at a dealership for 29 years, and now he is an independent. I have known him since '84, so I have learned to trust his advice. He told me that at one time Volvo put out a service bulletin about this issue, and urged owners who were experiencing the difficulty to up-size that fuse to 16 amp, if I am remembering correctly. Just go the next size
up; if it is now an 8, as I think, go to 16. Normally, I would not up-size a fuse at all, but I did in this case this three years ago, and that solved the problem. And, the wiring, fuse block, etc. does not appear overheated which makes sense, as the electrical demand in this area is not constant, rather it is just for the three seconds it takes to lower a window, etc. If you make this change, it is your responsibility, but I am just saying it worked for me.
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