Everything was disassembled, washed, dried, and then assembled, including my jury-rigged exhaust port diffuser of A/C foam, which I have been using almost from the beginning (2003) to keep the air from blowing on my spouse all night.
That night I kept awakening with the feeling that I wasn't getting enough air despite the fact that the blower output was working just fine. I kept trying to return to sleep only to be jarred awake repeatedly with the feeling that I was suffocating. By this time I also had a splitting headache. I finally gave up trying to sleep around 3:00am.
The next day, after my head cleared somewhat, I reviewed my data, and thoroughly examined everything I had done when reassembling what had been cleaned. Much to my chagrin, I discovered that I had completely taped over the exhaust port when I attached the A/C foam. Instead of using half strips of tape at the front end, I had used it full width which completely covered the exhaust port. A senior moment, indeed, as I have been using this diffuser for many years, and this is the first time this has happened.
This is a picture of the "dirty deed" with the arrow pointing to the completely taped over exhaust port.
