HVAC Blower working hard, minimal airflow

2014 Prius V (3rd Gen) 200,000+, AC blower: I can hear the blower speed change when I adjust the speed control. When it is cool, it blows a heavy airflow in the morning. However, after a while, later in the day while traveling, the outside temp is in the 80's. The AC sounds like something is restricting the airflow on high while cold air continues to come out. I selected different Blend door options, defrost, floor, and cabin; it sounds and feels like these are working correctly. But the airflow feels restricted.

I attempted a troubleshooting code test by holding Refresh&Auto while turning the power on. The system blinked for a while, only showing "00" on the display.

I noticed a 1' x 3/8" foam piece lying horizontal behind the three upper vents. I also recently changed the cabin air filter and double-checked that it was installed correctly.

Wondering if the issue has something to do with a possible temperature component. You now know everything I know; if I told you more, I would lying! ;>)

I value any input that can be provided.
Respectfully,

 

Air Boss,
No, the airflow does not increase when I turn the knob down.
If I remember correctly, when testing the system a couple of mornings ago, while the outside temp was still low and the airflow/fan was running correctly, the airflow did increase. However, when I turn the temperature control down during the afternoon heat of 82 degrees, the airflow does not increase.

 

Air Boss,
No, the airflow does not increase when I turn the knob down.
If I remember correctly, when testing the system a couple of mornings ago, while the outside temp was still low and the airflow/fan was running correctly, the airflow did increase. However, when I turn the temperature control down during the afternoon heat of 82 degrees, the airflow does not increase.

 

No, it does not increase. Were you able to see my previous detailed reply? Thanks Hutch

I will try to get some photos of the foam piece with the Bore Scope this weekend. Thanks Hutch

 

Yes, the fan speed seems to adjust by listening to the blower motor sound at all positions. However, it does not allow airflow correctly at all positions. I can hear the fan blower change speeds as I adjust the dial. Again, the system works correctly when the ambient temperature is cooler and not when it is hotter outside.

 

Yes, the fan speed seems to adjust by listening to the blower motor sound at all positions. However, it does not allow airflow correctly at all positions. I can hear the fan blower change speeds as I adjust the dial. Again, the system works correctly when the ambient temperature is cooler and not when it is hotter outside. Here are some photos I took with the Endoscope showing the questionable foam and one of the doors in different Modes.

 

I can hear the rpm's change when selected..

 

Hmmm, that may be an idea. Not sure how the enter workings operate. It may be possible a component has gone bad in part of the switch.

 

When the system is working incorrectly during the Hot day. It is almost like a "Box Fan" pressed against the wall. You hear the noise, but minimal air is being forced through.

 

<< Very good point about the foam. = Like.