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You may have done so but it's worth asking...
Have you checked the very very simple stuff already, as Landmann (who has helped me through my own fuel pump issues) is right in saying the engine is very sensitive to fuel filter issues - the pump's module is fuel cooled.

Had the same issues as you on my second pump. The smoke was so bad I ended up with people behind me on the motorway flashing me. A new, quality, fuel filter and a few tanks of premium diesel with redex injector cleaner (at about four times the recommended dilution!) and it's running better than ever now.

As you've had the head off it could still be anything mentioned so far, might as well check the really cheap stuff before you start throwing parts at it.
 

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I belive it's a Bosch VP44 pump you're dealing with?
Pull the diesel return line from the pump (not with the engine running) and see if the fuel coming out is clean diesel or if it's black and contaminated with oil.
Just a quick job to see if you you're pump is knackered.
 
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