Swapped back for the original all well(ish!) again. As per exactly what Bojan said - it was seized!! Happy to accept some egg on my face, here. However, I'm amazed it was, it got cleaned so thoroughly and with some light oil as an extra measure, thought it was moving freely. Anyway, I've had it soaking, poked around and got it moving again, it now moves very freely. Will have a look at swapping it back again, however, given it's seized on me once, I might not bother leaving it on.
Tonka - throttle body poorly adjusted was one of the reasons (as listed above) she didn't run right when I got her. Replaced with a good, low mileage TB, which has a dab of yellow Opel paint showing the screw hasn't been tampered with. Fully closed and back 'a bit' is, I think the Patented Marks DTM method of adjustment.
TB, thanks for the heads up, I never considered the butterflies as potential cause for airleaks. Will have a look. Reading Webby's post the other day I see they're interchangeable, which is nice to know, as I have a whole spare plenum which was pretty much going in the bin, but if the servos/butterflies are worth salvaging off it, as spares, then I will.
Baza, thanks for that, it's very much appreciated, I've actually got another spare, which I managed to find this evening. There's a mint 2.2DTi FL in my local scrappy, if there's anything at all you can think I might be able to get off it for you ( - very nice nick black steering wheel, for instance) in Z157.
My main worry was in leaving unplugged I managed to 'reprogram' something, as I've never been thick enough to forget to plug it in before.

Will report back when I've had chance to check out the butterflies and for other airleaks. Most likely around August 2023
