I just forced the flap open (to cold air) and drilled a clearance hole for a 10-32 bolt from the outside through the flap. I used washers and double nutted the screw on the outside. I kept everything else intact.

Tom

Removed air box and wax pellet. Used a nail in place of the wax pellet shaft to permanently keep the flapper open to the cold air side. Same setup can be done on the 240, just different air box. Back in the day, Volvo probably made some serious cash replacing AMM caused by failed wax pellets.

940 non-turbo 1993

I removed the air box from the car, removed the tube that contains the air flap & thermostat, separated the halves of the tube & removed the diverter flap. I then put everything back together, & plugged the hot air intake, using the screw cap from a jar (the cap is held in place with 2 screws). The flap went in my odd parts box, just in case it's ever needed again.

Yes, I have rigged the the flap in my 940 Turbo's airbox so it is permanently open to the cold, fresh air. I used some bailing wire to fasten it.

Please let me know if you'd like more info and I'd be happy to snap a photo for you.

Chris
'93 945T 183K

Depends on the year I would think.
My '94 945T has no warm air inlet to the box (it is closed off by a permanently affixed factory door) so for me, the answer is no.
I cannot speak for earlier models, not having played with them.

Yes. There are different methods to keep the flap diverted for cool ambiant only.
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David Hunter