Volvo Brothers and Sisters:
I need your help
While driving home my engine up an quit. Upon closer examination I found that FUSE 6 on my 1991 245 melted (the plastic) and fell out of the socket. Fuse 6 is the fuel pump fuse. I replaced the Fuel pump, thinking it was going bad, and it still heats up. It is the only fuse that does. I have checked grounds for the main pump the in-tank pump and even the fuel injection, all are clean and secure. Looking at the wiring diagram in Bentley's it seems to be a simple circuit (I can't find the fuse that is under the hood, behind the coil that bently says is there). What is going on here??? Why is that Fuse heating up???

John '91 SE Wagon
Aiken, SC

Another possible problem is the in-take fuel pump. If this is out, the main pump will strain and draw more juice.

-JSBB

Your fuse 6 replaced the 25 amp fuse near the coil. It should be 16 amps now.

Make sure the fuse contacts are corrosion-free and have good tension. Resistance there could cause the heat that melted the (plastic?) fuse. If it is a plastic-bodied fuse, look for the ceramic type.

I think a warm/hot fuse is normal there. All the current for the whole FI system flows thru it. Feel the FI relay some time.
--
Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.

The fuse can start to get hot if the contacts are corroded. Once the plastic has been cooked the copper contacts start to lose their spring, so poor contacts result, so the fuse warms up, so the plastic gets hot, and so on.
The best solution is a whole new fuse box, but the easier option is to find another fuse that isn't used and swap the wires. Mine doesn't have electric windows, so fuse 10 (I think) was unused. It shouldn't get hot if the pump and all the wiring are sound.