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An update.
We disconnected the return flow scatt tube from the firewall to the alu pipe that then runs to the heater and connected a vacum, blowing into the heater area. We got pretty good airflow through the entire front air system as a result.
We got some flow through the defrosters, but could also hear air escaping. Removed the AI and we could then see and feel a significant air leak between the lower plate and its mounting surface in the front side, just to the right and above where the scat mounts as you look at the setup through the AI hole.
For reference, in my parts book it is item 89 in figure 90, Cabin Heater & Defroster Installation.
We have tighened things up and sealed the area and it seems much better now.
We are also going to run with the floor vents partially turned off and see how it goes in the air.
In the process we also found a major pressurization leak due to the poor fit of the gaskets on the heating system intercooler, both top and bottom. Good news as the pressurization system was becoming a pain!
Regards - Dave
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