Hi Andrew, thanks for your input. I've been reading your thread about the fix!

So here's the thing, I do drop below 1/4 tank and fairly regularly at that. Especially if my wife has been driving as she won't fill up till its running on fumes! Several times on this trip in fact it would have dropped below 1/4 tank as otherwise we'd just be stopping for fuel 100miles sooner and making more fuel stops. In the last month we have filled up with the yellow light on and the OBC showing 20 miles range or less at least twice.

In this case then perhaps its just a dodgy fuel pump or filter? When we got it running on the tow truck the fuel filter did make the odd noise. Car has done 85k miles so barely run in compared to some of the Xs on here