Wow - this is a weird one.
It seems that the problem cleared itself after doing the above stuff. Temps have been a little warmer - but I have had it start with out a problem in -6 deg C (inside) temperatures. I'm not convinced its gone, but it looks likely.
Next step is to tear the inside apart and see why I was getting AC condensate in the passengers footwell.
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Black '02 Discover SII, Auto. 
Black '87 Suzuki Samurai, rock crawler  :
Black '94 Discovery SI V8i, 5 spd (Currently DOA)
--## If you have enough time to do something over again, you had enough time to do it right the first time. ##--
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