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This is a beginners guide. Anyone with a bit of experience wont need it.
The AC didn't seem to be blowing much air, when I looked under the dash near the passengers foot well I could see why.
There was a big gap between the fan housing and the AC evaporator housing where there should have been a seal. Heaps of air leaking out before it got cooled.
I forgot to take a before photo so retouched this one to show the problem.
While fixing the noisy fan I took the chance to remove the bottom half of the fan housing which let me fix the gap. Access is easiest if you remove the scuff panel from along to floor where the door closes, then remove the kick panel from the side of the foot well. This lets you get at all of the screws which hold the lower part of the fan housing.
I found more rubbish in this part of the duct work.
To fix the gap I got some concreters expansion joint which has a 10mm strip along the top which tears off easily. This gives you a piece of foam which is about 10x10mm. Added some silicone to keep it in place and it was just right for the job.
Only needs silicone on one side of the foam. It keeps everything in order until the fan housing is put back in place.
All done except for putting the fan in it's housing.
Finished.
Not hard to do, well worth the effort.
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