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Interesting. My Mondeo air-con only rattles when it's engaged!
I don't think the condenser would necessarily be goosed due to the compressor, but if the condenser has a hole in it, then all the gas disappears and the system doesn't work. The compressors are normally pretty robust. At least that's what I'm hoping for the Lotus, a new condenser is about £600.
Amyway, no point arguing if it doesn't fit. So a lot of labour later (ouch!) and another pattern part (UK-sourced this time) fits perfectly.
I presume the factory that made the first one is just inconsistent (it had the right number of teeth, width, etc). Not happy - might just about get £50 refund on the useless cambelt.