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I hook the motor up to the wires - not installing it to the shaft, then turn the car on and set the heat to high, you will see or feel the motor arm turning to it's max position. Then I shut the car off, move the flap arm to it's max hot position (towards the floor) then mate the shaft and arm. You still may have to move the assembly a bit.
Now my disclaimer to this is that I rewound my motor windings and didn't note the exact orientation/polarity of the windings and as a result setting temps to hot moves the flap to a cold air position, and vice versa, sheer genius.
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