Remove Splitter Wall and Air MIX Door Baffles

18a. For 1991 vehicles prior to VIN sequence 304903, remove separator screw and remove and discard splitter. Refer to Figure 1, View A.

18b. For 1992 and 1991 vehicles after VIN sequence 304903, apply a firm and steady downward pressure to splitter wall to disrupt the weld. (Preheating weld seams with a heat gun prior to applying pressure will assure a cleaner break.) Remove and discard splitter. Refer to Figure 1, View A.





19. Some early 1991 vehicles may need modification to the notch shown in Figure 2. If so, with a hot knife or hacksaw, extend notch on the heater/evaporator module to accommodate the additional retention tab. Refer to Figure 2.





20. Photocopy template provided in Figure 3 and modify P/N 52461742 to match template.

21. Remove programmer, heater core access door, and two screws holding core in place.





22. Using a 11/64" drill bit, drill out temperature baffle heat stakes in the temperature valve (air mix door) through the access provided by the removal of the splitter wall. Refer to Figure 4.