Arggh! I haven't happened to run across this exact problem as I think I understand it from your post. This control valve is involved but I simply don't know if it's stuck open or being told to stay open -- OR if a diverter door that would blend available heat and ambient air is the trouble??
Ya - I know these things get tucked in tight spots and aren't so easy to just get right at sometimes. Guess is that the "home" position for this is "open" flow and I'm guessing which isn't helping you much right now, sorry. Don't worry about the hose size as it's just lots more common to make the input hose smaller than the return hose.
Basically I've only deduced that this control valve is stuck, wiring or a vacuum hose to it isn't correct, or the control head (you don't want to go there!) is the problem. Not very good on my part so far.
Any ideas guys? I hate to suggest just tossing parts as a way to fix this.
If you wish come visit the folks at ACsource - just auto A/C discussions there and heaters are a major part of A/C work as heat if put head to head with A/C wins every time!
http://acsource.net/...644d7d8eeeb77edc058a See if that link get you to the Q&A part of that site if needed.......
T
Tom Greenleaf - MetroWest Boston - USA
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http://www.autoacsystems.com/tomgreenleaf/