Well, after an untold amount of me$$ing about, it's fixed...
Along the way I accidentally trashed the new piston kit, and the HBB body (didn't realise the new piston had not located in the spring properly...). Ended up buying a used HBB off ebay and making a "Best of" HBB using the best bits from the two units I had (including the new motor, new resevoir etc....)
BUT: The actual problem was this:
I did not know that Techstream does not report Brake codes (so I thought I had no codes). Neither did I know that that doesn't mean there are no codes. Nor that you can read them off the DLC3 connector. When I did this, it was basically reporting every conceivable brake code, including some which I knew I had not messed with (all wheel speed sensors).
Then the light bulb went on...
When I removed the Inlet pipe for a completely unrelated job a while back, I disconnected the HBB loom to ease access, and probably switched on the IGN with it disconnected.
What I didn't realise was that these brake codes do not appear to reset even if the condition clears. You have to do it with the DLC3.
Once I did that, the alarm went off, the pump worked properly, and all is good (on that front if not others) again.
What a palaver.
sim