Picking the right intercooler matters significantly to Volvo turbo enthusiasts. The Volvo community’s ongoing debate between 940 and 240 intercooler setups continues to spark discussions. These intercoolers have proven their effectiveness in turbocharged applications, each offering unique benefits.
Our team has dedicated extensive time to test and compare both options thoroughly. This piece provides valuable insights whether you want to upgrade your Volvo 240 intercooler or see if a Volvo 940 intercooler setup fits your needs. You’ll find detailed information about physical specs, installation needs, and real-life performance differences that will guide you to select the perfect intercooler for your build.
These two intercoolers have some interesting physical differences. Our team measured and analyzed both units to provide you with accurate comparisons.
The core volumes show that the 940 intercooler outperforms its predecessor by a lot. The 940’s core volume reaches 11,906cm³ while the 240 manages 5,377cm³ – making it 221% larger. The 940 model’s dimensions include a 29-inch top length, 20-inch bottom length, and 17.25-inch height with a core thickness of 2.5 inches.
The 940 intercooler shows a major upgrade in materials. The 240 model uses plastic components, but the newer 940 version features an all-aluminum construction. This material choice affects both durability and the unit’s heat dissipation and boost handling capabilities.
The end tank design is a vital difference between these intercoolers. The 940 model uses CAD-designed, flow-optimized cast end tanks that provide better airflow management. Tests show this design improvement leads to a 42% higher airflow rate at 0.15bar pressure drop. The 940 achieves 405 CFM while the 240 reaches 286 CFM.
The post-intercooler air temperature serves as a key performance indicator. Under similar conditions, the 940 intercooler keeps temperatures at 32°C. The 240 model runs much hotter at 66°C.
| Specification | 940 Intercooler | 240 Intercooler |
|---|---|---|
| Core Volume | 11,906cm³ | 5,377cm³ |
| Airflow (0.15bar) | 405 CFM | 286 CFM |
| Post-IC Temperature | 32°C | 66°C |
Installing these intercoolers needs careful planning and specific modifications. The installation process varies by a lot between the 940 and 240 setups.
The 940 intercooler installation needs specific mounting brackets that attach to the radiator support. The genuine Volvo intercooler bracket (part number 3514743) ensures proper fitment. The 240 setup needs more modifications to fit the different mounting points.
Our experience shows these modifications are needed:
Cooling system integration needs careful attention. The 940 intercooler installation in a 240 needs careful radiator positioning. The original radiator location requires extensive vertical metal removal. Automatic transmission vehicles need a separate transmission oil cooler to perform optimally.
Important Note: The NA 240 radiator works with a modified 940 electric fan shroud, but this needs precise trimming to fit properly. The entire cooling system layout should be planned before starting any modifications.
Testing shows substantial performance differences between these intercoolers. Our measurements under varying conditions provide accurate comparisons.
These units show remarkable efficiency differences. The stock Volvo 240 intercooler reaches about 81% efficiency, while the 940’s upgraded design achieves up to 97% efficiency. Temperature reduction tests show the 940 intercooler keeps output temperatures much lower at 32°C compared to the 240’s 66°C under similar conditions.
Tests at different boost levels document the 240’s performance:
Flow bench testing proves the 940’s superior airflow characteristics. The 940 intercooler flows 405 CFM compared to the 240’s 286 CFM at 0.15bar pressure drop. This 42% improvement in airflow enhances engine performance and thermal efficiency.
The 940’s improvements go beyond size. The end tanks and charge plumbing feature careful shaping that minimizes pressure loss and distributes airflow evenly. These design details make a big difference in ground performance, especially during high-boost conditions.
Temperature Reduction Comparison Table:
| Boost Level | Before IC | After IC | Reduction |
|---|---|---|---|
| 10.9 psi | 347°F | 133°F | <citation index=”6″ link=”https://www.240turbo.com/specsheet245.html” similar_text=” |
| 15 psi | 340°F | 77°F | <citation index=”6″ link=”https://www.240turbo.com/specsheet245.html” similar_text=” |
The compatibility between these intercoolers brings up several significant points we learned during our installations. Let me share what you should know about getting these components to work together.
A 940 radiator fits in a 240, but you’ll need to know a few things first. The non-air conditioning radiator from a 940 matches the 240’s dimensions, but the AC version comes wider. Our installations showed that bottom brackets need modifications and top brackets need custom fabrication for proper fitment. We recommend using a non-AC 940 radiator if you’re upgrading a 240.
Automatic transmission setups need special attention to cooling. The stock 240 radiator has built-in transmission cooling tubes. A 940 setup upgrade means you’ll need a different approach to transmission cooling. You can keep the existing cooling setup with connected transmission cooling pipes or add a separate transmission oil cooler.
Our installations revealed several modifications needed for proper piping fitment:
Important Note: The 1992-1995 intercooler piping needs major modifications to work in a 240 since the pipes must enter and exit from the top instead of the middle of the sides.
| Modification Type | 940 IC in 240 | Stock 240 Setup |
|---|---|---|
| Battery Tray | Required | No modification |
| Sheet Metal | Extensive | None |
| Radiator Support | Custom brackets | Stock fitment |
| Feature | Volvo 940 Intercooler | Volvo 240 Intercooler |
|---|---|---|
| Core Volume | 11,906cm³ | 5,377cm³ |
| Dimensions | Top: 29 inches Bottom: 20 inches Height: 17.25 inches Thickness: 2.5 inches | Not mentioned |
| Material Construction | All-aluminum | Features plastic components |
| Airflow Rate (at 0.15bar) | 405 CFM | 286 CFM |
| Post-Intercooler Temperature | 32°C | 66°C |
| Cooling Efficiency | 97% | 81% |
| End Tank Design | CAD-designed, flow-optimized cast | Standard design |
| Installation Requirements | – Specific mounting brackets – Radiator support modifications | Standard mounting |
| Construction Type | All-aluminum construction | Partial plastic components |
| Temperature Performance | Maintains lower temperatures | Runs substantially hotter |
The complete comparison between Volvo 940 and 240 intercoolers shows clear benefits of the 940 model. The 940 intercooler’s better design features a 221% larger core volume. Its all-aluminum build and optimized end tanks deliver 42% better airflow.
Our performance tests confirm these physical advantages. The 940 intercooler keeps post-intercooler temperatures substantially lower at 32°C while the 240 runs at 66°C. It achieves 97% cooling efficiency compared to the 240’s 81%. These improvements directly boost real-life performance, especially when you have high-boost applications.
Upgrading to a 940 intercooler needs more extensive modifications if you’re fitting it to a 240 chassis. You just need careful planning and execution for custom brackets, sheet metal changes, and cooling system adaptations. Our testing proves these modifications pay off for enthusiasts who want maximum performance.
Our hands-on experience with both intercoolers leads us to recommend the 940 intercooler for serious performance builds. Its superior cooling capacity and flow characteristics make it the best choice, even with the complex installation process. The 240 intercooler works well for mild builds or if you prefer simpler installation over peak performance.
Q1. What are the main differences between the Volvo 940 and 240 intercoolers?
The Volvo 940 intercooler has a significantly larger core volume (11,906cm³ vs 5,377cm³), all-aluminum construction, and better cooling efficiency (97% vs 81%) compared to the 240 intercooler. It also maintains lower post-intercooler temperatures and has superior airflow characteristics.
Q2. How does the installation process differ between the 940 and 240 intercoolers?
Installing a 940 intercooler requires more extensive modifications, including specific mounting brackets, radiator support changes, and cooling system adaptations. The 240 intercooler has a simpler installation process with standard mounting points.
Q3. What performance benefits does the 940 intercooler offer over the 240?
The 940 intercooler provides better cooling efficiency, maintaining lower output temperatures (32°C vs 66°C under identical conditions). It also offers a 42% improvement in airflow (405 CFM vs 286 CFM at 0.15bar pressure drop), which translates to better engine performance, especially during high-boost situations.
Q4. Are there any compatibility issues when upgrading from a 240 to a 940 intercooler?
Yes, there are several compatibility considerations. The 940 intercooler requires modifications to the radiator fitment, transmission cooling setup, and piping configurations when installed in a 240 chassis. Custom brackets and sheet metal changes are often necessary for proper installation.
Q5. Which intercooler is recommended for performance enthusiasts?
For serious performance builds, the 940 intercooler is recommended due to its superior cooling capacity and flow characteristics. However, the 240 intercooler remains a viable option for mild builds or those prioritizing simpler installation over peak performance.
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