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How I fit a 940t radiator in my 240

Ayce

Ayce

Member
Joined
Sep 7, 2025
first I want to say, obviously, I am no expert, this is my first time doing anything like this. I have seen only one other posts on this topic so I felt like I should post mine.

Photos

Basically what I did was:
get the intercooler in there where the rubber on the front was up against the ac condenser- this requires hammer,

measure from the points that the ic sits in on the radiator lower mounts and figure out where my holes needed to be for the radiator to fit directly vertical,

towards the front of the car, I had to bend the 940 rad support flat to fit on the flat 240 rad support. I actually had mistaken the rear for the front so I bent the wrong side. The only thing this changed was the lower rad supports don’t perfectly fit into their holes , they are prevented from sitting flush in the middle by the imperfect bends I made.

And the rest was just cutting and welding really. I made a template of the cut out that the radiator fits through on 940t cars, planning to cut out exactly that but I ended up just cutting a hole for the 940 rad to sit in.

i had to widen the metal behind the ac condenser (headlight support?) via hammer. I also had to cut notches for the intercooler in/out to fit. This requires bending the bracket for the ac component.

I also had to lightly clearance with the hammer for the intercooler to fit under where you put the tools.

I don’t think this would have been fun with the motor in the car. Also I have the water oil cooler system. I am annoyed that the radiator isn’t getting airflow below the mounts. I probably am going to holesaw 4 or 5 holes just for some airflow.

I am ready to hear how this will barely affect my cooling performance and how I should of just got a new universal radiator and fabricated something from scratch or better yet just left it oem

I am not done with this project yet. I still have to figure out a downpipe (using 940 dp), wire the e fan, expansion tank mount(annoying), figure out a battery, afr gauge , boost gauge, boost controller(not sure if I need it), and figure out if it all works. I am very happy with how the radiator figment came out though and I am super excited to get this thing on the road.

if anyone ends up doing this I encourage you to post about it because as far as I am aware thisreddit post is the only information out there. Maybe I am wrong.
 
Lots of TBers (particularly those who convert to non-native powertrains) fit the radiator from an NA 940 into the 240. I've not done it yet.... but certainly it can be done. I do recall they specifically use the NA radiator, NOT the turbo radiator. Nearly a bolt in, from what I've heard.
 
The Turbo cars got a taller version of the wide radiator, so it's not close to drop-in for a 240.

The n/a 940s from about '92- got the wide rad that is about the same height as the 240 rad.
 
I cut out the 240 piece entirely, and welded in the 7/9 support. then I found terminal rust, and cut it back out and scrapped the car.
 
Ayce said:
I am annoyed that the radiator isn’t getting airflow below the mounts. I probably am going to holesaw 4 or 5 holes just for some airflow.

I am ready to hear how this will barely affect my cooling performance and how I should of just got a new universal radiator and fabricated something from scratch or better yet just left it oem
Click to expand...
I'll be the last one to tell you to leave it OEM. There a line somewhere between making a chop mod and a mod that still look decent. If possible, try to make your mods look closer to maybe how it could have looked if Volvo offered the larger radiator (which they should have). I'm not sure why they didn't figure that out until 1992.

As for how successful it'll be, I think you'll find it performs a LOT better than the stock radiator ever could. But I also agree with the others that the non-turbo 940 radiator would have also been an equally huge improvement.
 
240 240 said:
a 3 row nissens radiator fits in stock location without all the fuckery
Click to expand...
Old tech, all my newer cars have thin wide radiators. My 242 has the NA 940 radiator and no problems with much boost in 100°F autocrosses, I also run the 940 water/ oil cooler, needed the tab on the coolant pipe welded on the other side for the water pump for my B23 with 530 head.
 
If I were to do it again, I would probably just modify the 240 support to fit the rubber lower mounts for the 7/9 Rad/IC package and then mount the NA radiator and intercooler there. Lot less cutting. Easier to do more neatly. Most of the benefits.
 
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