. . . heater worked until I replaced the stereo/CD player. There was no interefering recall work since.
. . I have pulled the radio and can put my hand into the cavity to make sure the cable and white plastic control mechanism moves when the dial is turned.
Here's a diagram of the mechanism on the side of the heater box. The cable comes up from the hot/cold control dial, and moves a lever which is attached to a vane inside that controls how much of the incoming air passes through, or by, the heater core. Is this the mechanism that you checked?
When you replaced the radio, and probably had to remove the heater control and disconnect the cable, did you have any difficulty, especially removing the cable? The cable outer casing has to be clamped in place. In the diagram it looks as if it's clamped to the mechanism. It might also have to be clamped at the temperature control end. If the casing isn't held in place, as the temperature control is rotated, the whole cable will move rather than just the center cable core, and so might not move the lever at the vane through its full range.
Both hoses are got to touch after motor has been running. Would this tend to show there is flow of the hot coolant into and back out of the heater core? Would this also tend to suggest no air blockage or other need for a flush?
Yes, it's a reasonable indicator of flow through the core. When the heater blower is on, and the cold air is passing through the heater core, the core outlet temperature might be lower than the inlet, reflecting the heat that was used to warm the air going into the cabin. But if the vane inside is bypassing the air around the core, the inlet and outlet temperatures will be closer. They could be checked with an IR thermometer held near each tube where it comes through the firewall.
Does that leave me with the issue of blend door or flap not moving somewhere. . .
On my 07, with the car off, parked in a quiet area (e.g. garage), if I turn the temperature control to the full hot end, at the last step there's a dull thud that appears just as the control stops. The sound appears to be coming from above the heater controls, perhaps from the center, face level, vents or just above. I believe this is the vane reaching it's fully closed position, (i.e., all air is directed through the heater core). I haven't tried this on another manual HVAC to see if all are this way, but it might be something to try. If there's no similar sound, then it's not conclusive that the vane isn't working, but it leaves that as a possibility. Of course, I could be wrong about the signifcance of the thud . . .
Sometimes i think I sense slightly warm air when the temp dial is in mid position. Does this help to suggest that there is flow in the core but no opening for the heat to come into the cabin?
The opening for the air to come into the cabin through the vents is controlled separately. If, when using the air conditioner, or even just turning the blower on high, there's plenty of air coming through the vents, and it can be changed from the floor outlets to the face-level vents or to the windshield, then it's unlikely the lack of heat is because of a blocked opening into the cabin. (I presume that even if there's no heat, the air flow when the heater should be providing warm air is as strong as when using the AC. Is this correct?)
Was your 09 subject to the front passenger airbag recall? If yes, was it done? And, again was this before or after the stereo work was done?