just took my 05 in and they said they had not charged it enough from the factory. they also put some foil insulation on the compressor hoses at the compressor connection. I went to home depot and got some of the black pipe foam insulation and wrapped the whole cold a/c line with it in hopes it will help keep the engine heat off of it....just did it so im not sure yet if it helped much...but for $2.50 it cant hurt.a simple test for the flapper door would be while in traffic, if you smell car exhaust when it's in max mode there is a god chance its not closing off good. also try putting a deoderizing (airwick) block on the outside vent below your winsheild and see if you can smell it when in max mode.

 

Can one just clamp the line in a pinch?