Greetings I have the strangest electical problem. When the headlights are turned on (car running or not) no. 6 fuse gets so hot that the plastic fuse will melt this fuse is supposed to run the fuel pump (1988 240 DL) which it must not because if you pull it while the car is running it will stay running.
The lighting question is more puzzling I have cleaned the grounds for all the lights, replaced the headlight relay, turn signal relay, headlight switch (jumpered in an older one) have not replaced the bulb failure relay because I don't have a spare. Sorry for the long post just wanted to be specific.

Since it was an unused fuse, perhaps it was used for a stereo or amp installation. If you've got anything other than the stock radio, I'd check the wires back behind the radio- pull that "speaker" grille on top of the dash if needed. The wiper mechanism is RIGHT up against those wires, and it shears them, causing short circuits.

Check that and be careful not to get any fingers caught in it- that could be nasty.

Good luck!
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Rob Bareiss, New London CT ::: Roterande Fläkt Och Drivremmar!

My guess is that someone did some "custom" wiring on your car. Fuse 6 should not be wired to anything on US cars (you are in US?) regardless of what the fuse cover says. It is for the Fuel relay in non-US K-Jet FI cars.

Does your car have any added lighting that might be involved?

All I can suggest at this point is to leave fuse 6 out, and see what doesn't work.
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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.

Yes, I belive that it did have a large stereo at one point.Yes Iam in the U.S. my car is from Calf. by way of Ohio to Michigan. When I pull the no. 6 fuse the headlights, taillights, brake lights (rear fogs do work) glove box light do not work and the lights on door open chime soundsuntil the headlight switch is turned off. The melting fuse has just started about 5 wks. ago. I did replace the bulb failure relay and headlight switch (correct one) both used ,still seem to have the same problem. Help, I'm loseing my tiny little mind.

Eric.
1988 240 DL "R" 226,000 mi.

I'm afraid this is no help, but here is how those items should be fused, according to the factory wiring diagrams:

Fuse 7 - Brake lights
Fuse 8 - Glove box light
Fuse 15 - Left side tail lights and parking lights
Fuse 16 - Right side tail lights, parking lights, and rear plate lights
Headlights are not fused at all

The door chime might be a clue to a faulty ground connection somewhere, as I recall posts on the subject. Maybe others will see something that I'm missing here. Sorry I can't be more help.

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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.

Last attempt was to move the power wire connecting at fuse 6 to the back row from the middle row and removing the fuse. Now there is headlights when switched to headlights( key on) and taillights and parking lights when switched to that setting but all will not light at the same time. Also the reverse lights don't work at all so, I will start there and continue on, thanks for the help to all. I will still be taking any suggestions.


Eric.
1988 240 DL"R" 226,000 mi.

Last attempt was to move the power wire connecting at fuse 6 to the back row from the middle row and removing the fuse

You may have partially corrected something, if I interpret your change correctly.

There are 3 push-on terminals for each fuse — one input and two outputs. If you can imagine seeing them in a side view, with the wires wires in your right, the top 2 connectors are on the fused OUTPUT side (Right fuse contact). The bottom connector runs under the fuse to the hot INPUT side (Left fuse contact).

I understand you to say you moved the hot (red?) wire from an output terminal (middle), to the back row (bottom?)where it belongs. If so, that's a start. Removing the fuse is good too.

Are there any other wires plugged there? If so, what color? There might be an unused Red-White,but that should be all.
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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.

It certainly is a strange problem, because in your US market 1988, fuse 6 shouldn't be connected to anything, the way I understand. The "fuel pump" labeling is for other markets-- that circuit being fused by the blade fuse under the hood.

Could it be some previous owner has done some re-wiring?
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Art Benstein near Baltimore