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Sounds like what I will be doing soon. I already installed one of the front speakers. I used 5 1/4 like you. I also have a 90 240.
On my front speaker, like you said, the holes don't line up, but I just held the speaker in there and drilled new holes right thru the plastic spacer. 4 screws hold it in.
I noticed one thing about the Volvo grilles. Your car probably has grilles that say "volvo" in white at the bottom, like mine did. If you go to a junkyard, you can find grilles that don't say "volvo" and on these grilles, the metal screen domes out more, so they will provide more clearance for the speaker in there.
As for power ratings, I usually ignore the peak ratings on the amp. It is good if the power rating of the amp exceeds the power rating of the speaker. This is because most speakers are damaged by "clipping" which happens when the amp reaches it's limit. If the speakers are the limiting factor, you will start to hear the sound distort when you really crank it, but the amp will not be at it's limit, and you won't burn out your speaks.
I have never heard of a speaker being damaged because it was overpowered. When you hear it distorting, then you know not to push it any more.
Greg Wong
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