High head pressure yes (according to a 2s AC technician), but no cooling, I wouldn't say that. There is cooling, but not the best. When I had the cheap evap. coil installed, the TXV and dryer were both OEM. Stock, as in.. never touched/replaced. Had the TXV and Dryer replaced too with aftermarket ones. But no difference in daytime cooling. It is most likely the cheap coil not being able to disappate heat effectively, when the sun's up. If the condensor was faulty or in need of service, the car wouldn't be freezing at night I think! And it is warm and super-humid at night in Khi, my friend!
I'll inspect the condensor again though, and check for that gap you mentioned.
Probably not the TXV. TXV and Dryer were both stock/OEM when I had the evap replaced. Cooling performance took a hit during the day, after that. Had the TXVand Dryer replaced with aftermarket ones, still same performance. Most of the evidence points to the evap not performing well.
Taking her to a 3s dealership soon. They said they do have the Rs. 11,700/- Thai coil (Paco) in stock, as nobody's interested in paying Rs. 32,000/- for the OEM one. Not a hot selling item. BTW, the one I have, is also allegedly a Thai one (says made in Thailand on the foam insulation, and a brand called Paco). Got it for Rs. 6,500/- though. The pics that I posted here, was being sold at an AC shop for Rs. 12,000. It doesnt have the Paco brand name on it if you take a look at the pics. Neither does it have "Made in Thailand" printed on it, but rather a tacky looking sticker!
I'm really hoping I don't have to replace the evap. coil again, and install the aftermarket one Honda is recommending. Who knows, maybe the system just needs a proper vacuum, coupled with the right quality/quantity of refrigerant and oil. These third party AC shops probably don't use the best quality refrigerant and oil, as opposed to 2s and 3s dealerships.
As soon as this cloudy pre-monsoon weather goes away, I'm taking her. In this weather, don't think I'll be able to get an accurate diagnosis. Where's the sun when you need it?!