Ok - update.
New head unit fitted and working a charm. Used the 'Ray Ambler' attenuator circuits on each channel, except the sub which I'm running straight off one of the RCAs, utilising a butchered RCA plug and the existing wiring.
And... WHAT a difference! I will now take back EVERYTHING bad I said about the HK stuff, with a decent input, at the right impedance level, it is MINDBLOWING for a 15 yr old standard system!! WELL worth holding onto if you have the patience to solder up 4 of those attenuator circuits. Great quality sound reproduction at any volume, with virtually NO distortion. Just goes to show you how s**te the Clarion head unit is!
And there's something else... I noticed that, with the original setup, the bass was particularly weedy. When I got the new head unit in and running, even before I'd connected up the sub, there was a HUGE improvement in the bass, even from just the door speakers. After some investigation, it turns out that the factory sub with the unmolested factory wiring was hooked up THE WRONG WAY ROUND!!! When I connected up the sub and reversed the polarity, the difference was unbelievable.
As a 'factory' system, with a DECENT head unit now fitted, it's a rival for any other out there. Seriously, I could not have been more wrong about the HK stuff - a crap head unit, combined with a 180 deg out-of-phase sub made the system sound awful, hence why I planned to replace EVERYTHING. I'm still gonna replace the sub and amp with one of my own choosing though - the HK one is strong, and ballsy, but it has no real 'guts' - I like my bass to shake the windows!
As a result, I will shortly be selling the original head unit, CD changer and sub, if anyone has any use for them. The HU works, the display is a little iffy but still readable. CD changer and sub work fine.