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Hi Ted -
I had a look at the Fuel Injection System, Turbo page, in my Volvo Service Manual Wiring Diagrams 240 1985. Book TP 30808/1 4500.7.85
Tracing where the power goes after fuse #6, here's what I see:
The red lead goes to the Pump Relay (terminal #30), where it goes through two sets of contacts to two outputs.
(1) from terminal #87, (Y-R) to fuse #4 then (Y-R) to the in-tank pump; and (Y-R)to the main fuel pump,
(2) from terminal #87b, (BL) to the grey connector on the firewall and thence to the control pressure regulator and also to the auxiliary air valve.
The contacts close when the pump relay gets power from the ignition switch and a signal from the coil. Then all that out-bound stuff has power, so any of those wires or units could be the shorting culprit.
The wires to the rear for the in-tank fuel pump goes through two separate connectors that appear to be in the area of the fuse panel or up above the driver's right toe. A nine-pin connector has a Y-R wire in and out from position #2, where #1 is a single GR wire and #3 is a double GR wire. Then the Y-R wire goes to a four-wire connector. There it is the only Y-R wire.
Disconnect the blue wire in the under-hood connector, and pull fuse #4. If #6 still blows, it's the main pump wiring. If #6 OK, then check with a test light across #4. Full bright means that's where the short is. If #4 is OK, that leaves only the under-hood components which also includes the possibility of crumbling insulation along the route.
Good Luck,
Bob
:>)
PS You might consider owning this book. www.volvocars.com/lit, choose service.
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