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"no visible signs of any components burnt. Is there a way to test the relay or jumper the relay connector?"
From your symptoms, I still suspect the relay. It could also be the switch itself, but this less likely since the relay now carries the heavy current. Do you have a meter, or better yet, a 12 volt Test Light?
If so, you can "back-probe" the relay plug to test for voltage on each wire, as follows:
With the switch set for Headlights, there should be +12 volts on these wires:
• Red/Green wire to terminal 30 (headlight voltage input) Unfused and always "hot".
• Blue/White wire to terminal 86 (relay "on" control) Also unfused, from light switch.
also:
• White wire from output terminal 87b (to fuses 15 and 16 for Parking/Inst lights)
• Yellow wire from output terminal 87 (to Hi/Low beam control relay)
NOTE: This relay has a unique output terminal (87 & 87b) configuration, and can't be replaced by just any Bosch 5-pin "cube". The Volvo Part Numbers below are from the 1992 Volvo Quick Reference Parts Catalog. The x-referenced Bosch numbers are from a 1991 "trade catalog" (S.A.V.E.).
240, 1986 -'93
Volvo 13247490-9 = Bosch # 0332-015-006 or 0332-015-013. I am currently testing a 013 in my 940, in lieu of the Bosch 006 that was in there.
--
Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.
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