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I think I figured out a large part of why the air coming out of the vents always feels much warmer than outside air or cabin air- half of the HVAC system's fresh air intake is under the freaking hood! I can't believe I just noticed that. As a test I taped over the under hood part of the wiper cowl to see if that makes a difference. The airflow does seem to be slightly less in fresh air mode with the under hood vent covered, but that should be easy enough to fix by enlarging the vent openings by the wipers and covering the openings with some type of screen to keep crap out.
The other thing I noticed is that even with recirculate on (and it usually is), there is still some air being pulled in through the exterior fresh air intakes. I also notice that some outside air gets forced in through the vents when driving down the highway with the blower off. I'm not sure if that's normal, I would think it should be blocked off. But my blend doors are slightly screwed up, so I wouldn't be surprised if that has something to do with it.
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