Ritey then guys, finally time for an update...
Starting problem was down to the starter motor - got a new one from Ford, and now it will at least start...

I have also taken the cooler back off, and re-checked all of the gaps on the CPS. They now all read at between 0.8 and 0.7mm, so in theory this will rule the cps out. I've double checked that the notches on the bottom pulley are in line with the sensor, and they are fine.

I have also attached another engine earth strap to the block in the same place as the original, and connected directly to the bat to rule this out completely.
I do still need to double check the gap on the phase sensor, but it was gapped to 0.2, which should be fine shouldn't it?


One thing it has now started to do is it is reluctant to start - will turn over and then run lumpy as fook untill you give it a rev, when it is fine... - Does this point to the Phase? - Its a new sensor - i'm guessing this then points to the wiring... - so what is the best way to check this?

Its quite frankly starting to do my head in - the car will be fine, then stutter, and then be fine again for another half hour... - also, it will start fine when hot, but not when cold.... (ECT is new also...)

Any more ideas guys pls?

Cheers