Thanks to all for your help, the flight went well (albeit long). For all those interested this is how the process worked:
1. Went to "International Connections" check-in desk at MEL
2. Picked up boarding pass at AC check in at SYD.
3. Picked up bag and cleared customs at YVR. Basically had enough time to clear customs, pick up bag and drop off at belt & clear security before reboarding flight to YYZ.
4. YVR-YYZ is a domestic leg so keep a hold of boarding pass to get some free food, otherwise you have to pay.
Overall experience is not too bad. Seats and IFE are not as good as new A380 & 77W SQ seats, but still OK.
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