Ok,
The additional relay may not be helping it's usually best to strip a circuit back to as original as possible.
The main pump drawing too much current isn't good is it noisy when the engine runs?
Is the in tank pump working properly? When this fails it gives the main pump far more work to do especially on start up there is also a short rubber hose that joins the fuel pickup in the sender unit to the in tank pump.
Out of interest how many miles had your Volvo covered so far?
Also the fuse boxes on these cars are pants I'm forever having to clean the fuse holders with a small piece of wet and dry paper.
Scott
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