OK...following my "Drinks like a fish" epilogue, the replacement engine is fitted, but whilst it no longer has an appetite for fluid, isn't exactly running like a beauty..
The rattling tappets on first start was most likely due to the lump sitting oil-less for a couple of months - that has almost settled down after it got warm - now more of a quiet sewing machine (will give it another oil and filter change the end of the week). Got me to work fine, but as soon as I started back home tonight, it started running on 2/3 cylinders. Moisture around no.4 plug suggests a pool of water had accumulated (maybe when it was outside Saturday night...). New plugs fitted tonight and its a lot better, but still a little rough.
Now sounds like the exhaust manifold gasket has gone west (might be the downpipe gasket as well) - but would either of these make it feel like it's running on 3 1/2 cylinders? I know it'll throw the mixture out as the leak will confuse the Lambda sensor.
It's also got a high idle speed which drops when i apply pressure to the throttle arm - now this should be fine as its the one from the old engine. Probably serves me right for cleaning the gunk out of it. Perhaps I missed a bit which is holding the plate open a minute amount?
Only 300 miles till the end of the week - dare I run it this long without getting the spanners out? There are some gen Vauxhall gaskets on ebay i'm about to buy so they'll be here in time for the weekend (unless anyone in the North Warks/South Staffs area with a Trade Card...).