That's a real poser, given the long list of things you've done and changed. I agree, try and find out what's missing in the "no start" condition, is it missing spark, fuel being injected or both? This will hopefully help eliminate a lot of things. Remember just because you have fuel pressure at the rail doesn't mean that the injectors are firing and injecting it, so see if you can determine if they're actually firing. Spark is easy to test for, but injectors actually firing and injecting fuel more difficult, but equally important.
Will be following this one with interest!
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