Hi All,
An update to this...
I ordered a Mahle condenser from carparts4less - they had a BH discount so came in at about £90. What arrived was a Hella Behr, made in china and painted in black which is slightly different to the one that was on the car as it was plain aluminium. Anyway looking into it, painted black condensers apparently makes them more efficient at radiating heat. Came with a couple of new locating pins but no o-rings so I got a couple of the HNBR ones from BMW.
So I then started work on the car. Removed the fan, the cross member brace thing, and plastic cover on top of the radiator. Removed the hex bolts on the AC line connectors to the radiator, and what followed was an hour long frustrating exercise in trying to de-couple the lines. Seems that the alignment pin was siezed onto the connectors. Took some careful wedging of screwdrivers and hammering to get them to separate. There was some damage to the mating surfaces, but none where the o-rings meet the receptacle in the condenser. Applied new o-rings to the lines, and tried to get the connectors back on. Struggled a bit again. The locating pins on the lines appear to be fluted, and pressed on. I couldn't remove them to replace them with the new ones that came with the replacement radiator, so had to live with the ones currently in place. The depth of the receiving hole was a little narrow and not deep enough, so I just carefully drilled down into them on the new radiator and managed to get it all connected up.
Took the car for an aircon service expecting leaks from the connector area. Took about an hour as they evacuate, re-fill and test for leaks. They reported no leaks which is a result - let's see how long it lasts!
