Took the air intake grill off and found that debris had been blocking the heater box drain pipe....along with two of the missing metal air intake grill retaining clamps! As Derek says, the hose gets bent and forms a further constriction. Cleared it out and flushed it through which seems to have resolved the immediate leakage problem However, I'm still going to strip down the heater to inspect the matrix, heater drain plug and get it painted. Derek - do you have any of that foam left for wrapping the matrix as I'm sure mine's going to disintegrate.....
Thanks
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