Is this doable?I have seen about 6 91 and up 240s in some boneyards.I know I can source all the parts to make a complete system,hoses,compressor,condenser,aux fan,blue switch,relay.Am I missing something.oh yeah the bracket for the compressor.But is this the way to go for maximum 134a cooling?It looks like a better system with all components in the engine bay.

I did the swap on my '87. I had the luxury of a '91 donor car, so that made things a little easier. I used the compressor from my '87, but the rest of the parts came from the '91 including all the wiring, hoses, firewall plate, evaporator, condenser, switches and relays. I was in the process of changing out my heater core and blower motor at the time, so I swapped out the heater box from the '91 too. I would recommend changing the evaporator because the one from the newer model is bigger. The auxilary fan is great, especially if you are going to use R134 refridgerant. The biggest problems were in the removal of the center console and with the wiring. Make sure you have wiring diagrams from both year cars so you can compare diagrams when doing the swap. Good luck!

FWIW only the 93's had the factory R134a systems. I don't have enough experience with diff 240's to know if it really works better than a converted R12 system or not.
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'63 PV544 rat rod, '93 Classic #1141 245 +t

I'm told by the local Volvo repair guy who's been working on these for 25+ years that these are the best systems on a 240. It's definately do-able. I just finished putting a system from a '92 into my '82. I'm not sure but I think that your compressor's the same but I don't know about anything else. You see, I converted from the old York compressor which is completely different than the '86 on style. For me, everything from the heater box out had to be replaced. The wiring wasn't as bad as I'd anticipated once I got it figured out. Also the passenger side firewall panel had to be replaced as well. The front core support was different so I had to custom mount the condensor. The front horn support post was different so I got that from the '92 also. You'll have to drill holes for your lines clamps where they were on the newer ones. I haven't put the car back together yet as I'm waiting on a power mirror wiring harness before I can re-assemble. The power steering setup had to be replaced as well from the '92. You'll want to replace the accumulator with a new one as well as the conversion kit will have to be installed if it hasn't been done already. Mine was already done. The easiest way to do it is to have a donor car but it doesn't sound like that's an option for you. I'll post with results when I get it completed. Good Luck! Charles

Sounds like a big project,although it may not be as bad on a 'newer' car.I need to hear from someone who maybe has a 86-90 and also owns a 91-plus.I cannot imagine that Volvo would have changed much in the way components fit knowing that they were going to eliminate the model in 3 short years.Does anyone know if the compressors are the same?Aside from the firewall I think things should just bolt right in.Thanks for sharing and let us know how the cooling is.

Hi there,

In my stable are two 89s, a 90, and two 91s. There's definitely a great deal of difference between 90 and 91 - the txv system vs the orifice tube GM type. I hadn't thought about grabbing the components from a 91 to retrofit, although I have installed the Volvo kit in a 90 which includes the evaporator.

Here are a couple of pics I recently posted to show how the 91+ ac components make it a rougher job to change the Crank Position Sensor (CPS) at the top of the bell housing.

You can see the 91+ AC components literally take away the elbow room to work behind the head. What is not so obvious, is when the hard aluminum piping needs to be moved to replace the heater core on the other side of the firewall, this later GM system becomes a liability, unless of course, you can get it recovered and refilled.

But the advantages for cooling can tip the scales - it is so much easier to convert to R134, and, with the 91+ condenser fan, has a chance of being successful.

I don't know that the compressor or AC bracket has changed 90-91, in fact I rather doubt it, but I believe the hoses and piping are indeed specific to each one, judging by my memory from Monday, attempting to connect a gauge at the compressor test port before remembering the one by the accumulator.

It does still look like a project. And I am fairly sure the hard-line connected evap is a longer and round-ended shape that will not fit in the pre-91 heater box. Surely there are many on this board much more concerned, and knowledgeable, on the subject of 240 air conditioning, especially those living in Florida, who could fill in the details for you.






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Art Benstein near Baltimore

To err is human, to moo bovine.