The 89 240 received a majot tune up totay including water pump, FPR, O2 sensor, throttle body cleaning and electric fan conversion. The water pump was making a knocking noise ever since we bought the car 3 months ago. Mechanic told the previous owner that it was rod knock. Wrong! I found about 1/4 inch of play in every direction when I pulled on the clutch fan.
I was going to use a GM FWD electric fan but when I found the 940 fan with relay for $24 I just had to have it. After some careful cuting it fit like a glove and looks stock. This left so much room between the engine and the fan that now I can work on the belts, tensioners harmonic balancer without having to remove the gigantic shroud and fan or the plastic cover under the engine. I was even able to install the new water pump with the electric fan already in place.
With the electric fan the engine is much quieter inside and out side the cabin. Despite what some would have you believe, I did feel a major difference in acceleration. I highly recomend this modification to any 240 owner.


This is the fan switch. The 940 fan is ground switched. The switch is mounted in a hose adaptor from a 1980s Saab 900. The Saab used a 110/115 switch in the upper hose. I used a new 87/92 switch in the lower hose. This switch activates high speed. The low speed is switched by the AC compressor clutch.




Looks stock




Before


After. The only proper way to clean the TB is to disassemble it completely. Then I had some fun with the Dremel.

I understand your point about Volvo installing this fan in their 940 models, I see them all the time in the wrecking yards. Yes, that particular vehicle that killed the battery was a Chevrolet. If I could go back in time I would have installed a higher output alternator and 2 batteries. I feel like looking into it, but I'm almost sure Volvo uses a higher amp alternator in their 9 series models. When I killed my battery I did it at night with the lights on and it was a warm night. Stop and go in warm or hot weather like we have on the west coast may bring the cooling reliability factor of an electric fan into consideration. If your in cooler weather and your not in large traffic jams your probably okay. Doing some real driving with an electric fan (stop and go, climbing 10 mile hills, possible traffic jams) in our deserts (trip to Las Vegas) out here on the west coast in the summer with 100 degree temps might be a little scary as you are really testing that electrical system. As you probably already know, Volvo does have electric "pusher fans" installed in conjunction with their manual fans on their newer 240's and older 240 Turbo models. Of course these should be designed to assist with A/C. Others use them to increase Turbo boost.

I've seen a lot of "used" 940 fans in our wrecking yards and considered the switch. The only thing keeping me from making the switch is that I used to have a hotrod with electric fans and I became stuck in heavy traffic. The fans killed my battery and I was screwed. Do 940's have higher output alternators than 240's? Thats the question you need to ask.

I can't speak for the 940 but the 89 240 has an 80 amp alternator. I am using a 30 amp fuse for the fan. I so I know it draws less than that. Another thing to consider is the ammount of cooling the fan has to do. I have driver about 200 miles with the fan and it seems to stay on for 30 second cycles every 2-3 minutes when stopped in traffic. There is no way this fan can run down a half descent battery. Volvo used the same fan on the 940, 940 turbo and 960. So its designed from the outset to cool 200hp. 114 hp is a breze (pun intended). A hot rod (american V8 I persume) generates far more heat than our lowly B230f engines.
I think its also important to remove the compensation circuit from the temp gauge if you do this mod. Good luck.

This may be a good reason for having a voltmeter in your dash. But failing that, you can put a voltmeter across the battery and, with the engine idling, trigger the fan relay to turn the fan on. Then see if ongoing operation begins to draw battery voltage down. If not - no worries, but if so, the permanent dash voltmeter would show you when to speed up the engine a little when idling in traffic.
--
Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and numerous old motorcycles)

I agree totally. A vast inprovement to noise level, some acceleration gain, and some mpg improvement. Incidentally I think the recommended position for an electric fan is in FRONT of the radiator. This of course gives you even more space inside.

- Incidentally I think the recommended position for an electric fan is in FRONT of the radiator. This of course gives you even more space inside.

It depends on the design, pusher or puller. Both the GM and later Volvo fans in context are pullers, designed to go behind the radiator and pulling the air through. Pushers go in front. It's all a matter of what's available.

IMHO, the vintages can do either, but the later RWD's are better with a puller because the lack of clearance from the front mountings to install a larger pusher.

-- Kane
--
Blossom II -'91 745Ti/M46 ... Bubbles -'74 144GL/BW35 ... Buttercup -'86 245GL/AW70
The Wayback Machine -'64 P220/M40 ... The ParaBox -'90 745GL/AW70

Most OE fan arrangements are pullers. This is the most efficient arrangement, as proper shrouding allows all the air moved by the fan to be directed over the entire rad core. Another advantage is that the fan's motor is somewhat screened from insects, road debris and moisture by the rad and the AC condenser.

And yes - very nice, clean installation!
--
Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and numerous old motorcycles)

Very nice work and a great idea! I am sure you will find the car a lot quieter with the engine driven fan removed.

Hello!

Brilliant idea! I'm eager to repeat your experience on my car in the future. Could you please prompt me the model of that GM FWD electric fan you wanted to use first?
Thanks a lot.

Dmitriy.

--
240DL 1987 silver-blue wagon, >240K miles.

http://www.linkline.com/personal/dbarton/fanconversion/

This is where the origininal idea came from. Its a very good source of information. The GM fan from 1980s FWD "A Cars" has a shroud that fits perfectly over the 240 radiator without any cuting. These fans are pletiful and cheap in American Junkyards.

Beside a Dremal tool, what kind of chemicals can you use to clean your tb?