Couple more hours at it and job done. Had to do a combination of removing leccy fans via the front and condenser out from rear between rad and intercooler.
Popped out front indicators,removed front grill and light surround again (had to put it all back together yesterday to pickup/take Mrs to work)
Slackened off the bonnet catch mechanism to free the tops of tie bar rods. Removed bottom fixings for tie bars (rusty pigs replaced with 316 stainless).
Tried to undo the 8 hex screws that fix the fans in place but every one of the head sheared off... good though as it made job quicker and easier ! Un-plugged the two fan connectors from loom and wiggled both fans out via front, careful not to damage the automatic gearbox oil cooler.
No way to remove the condenser panel from the front but no need to drain down coolant system to remove from rear either. Removed top rad hose and caught the litre of coolant in a wide tray. Removed top intercooler hose. Removed fan. Removed fan surround. Removed top rad panel and released both side brackets. The rad and intercooler can now be eased up and tilted backwards to give clearance to the condenser panel. Only two bolt at top fix the condenser in place. Bit of careful wiggling the whole panel can be lifted up and out between slam panel and rad/intercooler.
Cleaned out the 6 inch high debris that had built up between rad and condenser. Waxoyled the cavities around lights and body mounts at front while I was able too. Put everything back together with top up of coolant and oddy enough car feels better for it
! There is certainly a lot of room for air flow now and some dead weight gone. Think there is room for a larger intercooler now.
I am not in camp of fitting offroaders with leccy fans for cooling nor in camp for removing the standard fan from a tdi so that's staying as is.
Enough of playing with disco for moment, got the defender to rub over with oily rag as it's MOT time coming up.
