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Well, you won't take a bath if you separate it- there's only air in there. It's the fan housing and ductwork. Yes, to take it off you'd need a lot more of the dash apart. Your 91 has the knee bolster under there too which makes it 10 times as much fun. You should be able to pop it open enough to get it, or even if you crack the white plastic a little, some duct tape (from your Dept of Homeland Inferiority Survival Kit) will fix it up- honest! I know access is tight under there but keep at it.
Dave has some good pictures of what's in there on his site-
http://www.homestead.com/volvo2/Dash.html Lots of other info there too.
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Rob Bareiss, New London CT ::: "Roterande Fläkt Och Drivremmar!"
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