Volvo Repair: 86 240 Series 4DS intermittent electrical problem, haynes book, loose ground


Question
 I know this is an older model, but I was hoping you may be able to at least point me towards more information.

 I recently bought this car, and after a few months of driving it would sometimes just not start.  Electrical would come on, but the engine wouldn't turn.  My dad thought it might be a loose connection somewhere, and after checking the fuses and jiggling the wires under the driver's side dash, it started just fine.  After that it has occasionally died on me, but otherwise has been working perfectly.

 I took it to a mechanic who said it was the outside tank fuel pump, charged me $80 to fix it, only to have the same problem come back a few weeks later.  

 The previous owner of the car installed a cd player in place of the radio and I'm worried that either that is the problem, or maybe he could have shaken something loose while installing it.  It's only happened a few times, but sometimes the cd player will just power off and not come back on for awhile. I'm trying now to check if the installation is correct, but I only have a wiring diagram from for a 1976 from my 76 through 93 Haynes book.

 He's got the red ignition wire from the radio wired to a blue wire and black to black on a relay on the bottom left side of the middle console, which is unidentified in my manual.  There are also three wires from the relay that have been capped.  

 Is there any information or recommendations you can give me?

Answer
It seems so random i really don't know where to start.  If the car was in my shop I'd jiggle some of the wires you were talking of and do whatever i can to recreate the problem.  You can only find the problem if it exists.  It sounds thought like it has to be a loose connection, loose ground or short.  Possibly caused by the radio install?.  The wiring diagrams should be accurate that you have if its for that particular production run.  Very little changes until the model is redesigned.  The wires that you are describing to me don't sound original.  The previos owner may have done the radio install takeing a few short cuts.  Generally with the radio though, the red is power, black is ground or antenna, the colored wires are speaker outputs, and the blue is the remote signal from the ignition that tells the unit to turn on.  Hopefully you can get that mess straigh so you can find the real problem.  If you are still have problems, I recommend taking it to the dealer.  Usually their hourly rates are only 10-15 dollars an hour more than an independent, plus you get the dealer equipment, and expertise.  Even if they get it wrong, you can come back and they are obligated to fix it again for free.  Thats the best advice I can give.  Good luck.  Hope this helps.

James