Okay, this is where I got scared. Too many things were popping up and shaking my confidence, and I wasn't sure I could deal with them all. Plus the wife was getting pretty unhappy about the amount of time this was taking. We aren't mentioning the cost...
I ordered two 40mm M7 fine bolts, (or were they 50? Maybe) so I could bolt the camlocks down more securely, cleaned out the thread in the head, and crossed my fingers.
Then...A mechanic friend offered to take on the job that I decided was too hard, and after a few adventures I got the car relocated to his ample workshop (next to his 20m of railway track containing a working shunting engine). He pulled the old engine out and set about fitting the belts, water pump, idlers and tensioners that I had started on. Most items were identical between the 1.8 and 2.0 motors, but for simplicity's sake he swapped the engine loom over, and used our existing known to be good alternator, power steering pump and aircon compressor.
The clutch was good in the 1.8 but the 2.0 has a larger pressure plate - and was practically new, so we swapped that over. The concentric thrust bearing had a bit of a rumble so he put a new one in ($220 plus GST. Ouch) The gearbox was filled with fresh Castrol VMX and the whole unit poked back in. A bit of swearing about access to alternator bolts and so on was apparently done, but in the end it fits in there like it was designed for it (it was), except that there seem to be some slight differences in the pipework to the AC - Chris had to let the gas go in removing the engine, and putting it all back together saw the AC pipes touch the fan shroud. fingers crossed over that one...
Once in it was filled with appropriate fluids - magnatec and a new filter, nice green coolant, power steering fluid checked, etc, and fired up. It runs happy as a clam except for the second time I tried to start it, when it went into shutdown - we suspect low battery voltage triggered an ecu problem, but jump starting it it fired up, and has run fine (on the same battery) since.
It spins up fine, pulls hard, sounds good - to be honest it's so long since I drove it as a 1.8 I can't tell you whether the extra torque is noticeable but it isn't any worse anyway
So - success. The only 1.8 in the country is now on 80000km 147 CF2 2.0 power. With all new bits on it.
Total cost -
new engine $750
belts etc $500
further parts like the clutch release $400
labour $1000 (30 hours at $30ish - a bargain hourly rate but still ouch)
and I'll need to regas the aircon
so the car had better behave impeccably for three years...