I've tried a L8 from a friends saff 4x4, and it still wouldn't start, unfortunatly my friends saff has a broken cam so can't check the escorts ecu on it, but his was a working unit.

I've checked the sensor gaps, there are the same as when it was working, and the teeth are in posistion and ok.

We have the phase/cam sensor set at 0.3 and the TDC at 0.6, which worked before, the phase/cam sensor seemed to not work the further away it was set.

The phase/cam is a cosworth type TDC sensor.

Have you tried it closer.