Great info, thanks guys.
We've decided to go with what we think is the easiest option: we've booked the injured chap, his mate, and their bikes on to the same ferry to Barcelona that my husband and I already had booked for Wednesday. The injured bike owner will take a taxi to Tangier Med, with us following the taxi. He'll then hobble in with us to customs, or possibly go on the back of our trike if he's up to it (it's his knee that's injured). That way he'll be there to deal directly with customs, and will be with the bike in question - I'll just be riding it. Should work, we hope - can't see any reason why not!
Once we're all back in Spain he'll go to hospital and get a proper diagnosis so that he can then use his ADAC cover to get him and his bike back to Germany.
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