Evening Shaun,

Just a few thoughts. I would have thought you have got the Crank Sensor in the right place because it runs Ok. The clue is in the starter motor. When under high load ie: when cold the vehicle fails to start but on a push start the vehicle goes ok and also when under low load when engine hot. Is it possible to measure LT feed voltage to the coil when the vehicle fails to start in case of excessive starter draw? Also, I remember many years ago on little Fords that the main lead to the starter motor would interfere with the crank sensor wiring due to its close proximity on cranking causing non-start. I got round that by insulating the crank sensor wiring using silver foil and tape which solved the problem. Probably not the answer but something to consider.

Rgds

Pete M