Have you checked the high pressure rail sensor for corrosion? I didn't see it mentioned above.
I also think you can't rule out the 2nd hand sensors you've changed. I know you don't want to chuck money at it to eliminate a fault with unnecessary replacements but if the problems persist after replacing those parts with used ones (whether OE or not) you can't be sure if they are the problem or not.
How many wires do you have going to the in tank unit?
Just the 2, the green and the black.
Thanks nodge. Is it still worth checking the filter on the bottom of the fuel sender anyway?
The fuel pump in the rear arch is relatively new as we replaced it with a new pump and filter approx 4 months ago. Primes ok when ignition is turned so assume all is good there.
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