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Stick with the 4-inch, as the rears will provide all the bass you need - up til you decide on a subwoofer.
Be sure the mounting depth of anything you put in the front doors won't foul the window mechanism or glass. 2 inches is all the room you've got.
Crutchfield will sell (or maybe give) you a mounting adapter that will fasten the spkrs to the door panel, help seal up that cutout so you don't get phase cancellation of certain frequencies, and which can mount the stock Volvo grille, even if the grille's pegs are broken off. That's our setup on both 240's.
My son's car had those Kenwoods...nice and smooth with a rather bright top end, but lasted only about 2 yrs. Then the Polks (GRX-4?)went in and one of them is now buzzing and distorting. It's a tough life in those front doors. Go for durability over high-fidelity - heck, it's a noisy old 240!
I'm planning to put those "bass-blocker" capacitors on the leads to the front spkrs - they can't reproduce frequencies below about 100Hz anyway, and maybe it's that low frequency power that's helping mangle them.
Smallish wires like 18-ga will be fine, there isn't much power going to those front spkrs. Most are not recommended for more than 20W continuous (that's LOUD), which translates into a bit over 2 Amps into a 4-ohm load. It only needs a VERY small wire to carry that. You want a bit bigger for the occasional peaks, but 18-ga would be plenty.
--
Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and a few old motorcycles)
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