At £300 I presume she must have had a new egr valve fitted
it's around £30 to £40 to delete the egr with the new kit, I'd blank the vacuum pipe for starters.
has anyone recommended checking any of the rear suspension, as I have read on here so many times, peeps think that it is coming from the front, when in fact it is the rear.
I also see you haven't mentioned the anti roll bar links, these can be easily seen when you move the wheel on lock to lock, there is also a washer on the top fitting, I don't know which side it's supposed to go on, but I'm sure pete, haylands on here said it has to be fitted a curtain way, or it causes a knock.
I have fitted a set of britpart upper arms on mine, and so far they have done approx 20k, with no issues, I was fully expecting them to fail before now, they don't have a very good reputation.
As above advice, there is definitely something amiss, although I find it hard to believe that it's the same item over snd over.
hope hou get it sorted for your sis.
greg 
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