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940 turbo intercooler in a 240 (10 year 2024 bump!)

Thor

Active member
Joined
Feb 20, 2007
Location
Nebraska
Can someone show me how you mounted a 940 intercooler into a 240. I have one from a 94 940t

debating on this or forking more money over to get a better ebay or NPR cooler. I know what would be better performance wise but the 940 one is free.
 
Like I said I already know what option is better. I already have the 940 IC though and I'm cheap.
 
give me a minute. I am using an intercooler, just don't know where it came from :) I will Edit the post after the pic has been taken! :)

Adam
 
Sure it can be done. But you should use the IC pipes from the same car as the IC comes from.
The big IC from 900 with AC fits perfect in front of the cooler. Cut out the sides a bit and this is the result.

The first is from when I turbocharged a b230f and wasn't so serious...
IN the second pic you can se how clean it looks :)

2z5u54m.jpg


54sz0p.jpg
 
^ Since it sits below the cross member in front of the radiator with a bit of trimming. What are you using to hold it into place?

Thanks for the Photos!
 
Sure it can be done. But you should use the IC pipes from the same car as the IC comes from.
The big IC from 900 with AC fits perfect in front of the cooler. Cut out the sides a bit and this is the result.

The first is from when I turbocharged a b230f and wasn't so serious...
IN the second pic you can se how clean it looks :)

2z5u54m.jpg


54sz0p.jpg
Anyway we can access these pictures?
 
The previous owner of my '92 240 installed an IC from a 940 and used the piping from the donor car.

The corner of the plastic battery tray (where the clip thingy clips on) was cut off to allow the IC pipe / end tank to clear the battery tray.

117126056.jpg


In my experience fitting one of these to a different 240, you'll need to trim some sheet metal in front of the radiator, on either side.

I swapped the cone filter for a 240 Diesel air box and rearranged the piping into the turbo a little bit.
162359923.jpg
 
Anyway we can access these pictures?

It's not the same guy, but I did this on my 93 240. It involved cutting the spot welds and removing the stock rad support, then cutting up and welding in the late 7/9 rad support. This allows you to fit the complete late 7/9 Rad/IC package. You could probably get away with less work if you used an NA 940 radiator, as they don't extend below the mounting point.

You'll also need to remove some sheet metal behind the grille on the 240, there's a fairly easy to see and follow line where it bends, and I just cut along that.

I didn't get my positioning quite right, so I'm gonna have to cut my mount out and move it up by about an inch/inch and a half, and back by maybe half an inch. That way, the top of it will engage with the stock 240 radiator mounts, and there will theoretically be room for the 940 condenser to be put in at some point. I did it so the install will look fairly stock, and because I plan to someday drop in the do88 radiator and IC.
It's probably not worth the effort, but it's what I wanted, so I did it.
 

It's not the same guy, but I did this on my 93 240. It involved cutting the spot welds and removing the stock rad support, then cutting up and welding in the late 7/9 rad support. This allows you to fit the complete late 7/9 Rad/IC package. You could probably get away with less work if you used an NA 940 radiator, as they don't extend below the mounting point.

You'll also need to remove some sheet metal behind the grille on the 240, there's a fairly easy to see and follow line where it bends, and I just cut along that.

I didn't get my positioning quite right, so I'm gonna have to cut my mount out and move it up by about an inch/inch and a half, and back by maybe half an inch. That way, the top of it will engage with the stock 240 radiator mounts, and there will theoretically be room for the 940 condenser to be put in at some point. I did it so the install will look fairly stock, and because I plan to someday drop in the do88 radiator and IC.
It's probably not worth the effort, but it's what I wanted, so I did it.
I started by cutting the vertical sides of the radiator support until the ic could move up more. The ic has these little feet on the sides of the end tanks and I'm going to make slots in those so I can rest them on studded bushings that I'll fasten to the bottom of the radiator support. I trimmed the top of the ic so that it fits in the groove in the top of the radiator support. Once a rad is mounted behind it using the factory clamp type things I think it will be pretty solid. I've been playing around with rubber edging and gasketing to make it fit better too.
 
I started by cutting the vertical sides of the radiator support until the ic could move up more. The ic has these little feet on the sides of the end tanks and I'm going to make slots in those so I can rest them on studded bushings that I'll fasten to the bottom of the radiator support. I trimmed the top of the ic so that it fits in the groove in the top of the radiator support. Once a rad is mounted behind it using the factory clamp type things I think it will be pretty solid. I've been playing around with rubber edging and gasketing to make it fit better too.
I also went with the na 240 rad and trimmed the 940 electric fan shroud down so it will fit the 240 rad.
 
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