I didn't get anywhere with the heater on Saturday afternoon, so button it all back up and thought the mode control was roughly working. Nah, on a 5am commute the other morning clear screen setting kicked in (I didn't test that earlier) and the heater did zip all except vent to the rear seats! For the entire 4hr round trip
At lunchtime I went back to basics and figured out what lever on the heater does what. I also removed the 2 servo's/mounting plate and let them do their thing. Once I had a grasp of ALL the settings (temp, modes) I set all levers in roughly the right setting, lined the mounting plate to the heater arms (no easy feat), restarted the vehicle and the first test failed
I have noticed that when you turn off the ignition, the servo's sit for a while and then revert to some standby setting. I think this has been throwing me off so I removed the servo plate, set all levers in roughly the right setting, fired up the ignition and let the servo plate settle. With the ignition still on, I aligned the mounting plate to the arms for the umpteenth time and gingerly pressed a different mode button...
The first test worked and the servo's didn't bind, try another mode setting and that worked. Trying not to freak out I carefully went through all the possible combinations and to my delight they all work
The passenger side footwell output is still hopeless tho I think I may know which control needs a slight tweak but then it may just be the way the airflows. Rather than dismantle it all again I reckon I'll buy the mrs a heated blanket/mat or fan to keep her feet warm.
To help align the 7? heater control arms to the servo plate I found one of these cheap endoscope camera's quite helpful to help see around corners http://www.ebay.co.uk/itm/122076843254
Oh and this time there are NO spare fixings left over LOL