Still fighting with my friends 2004 2.0 diesel C-Max, turns out the cam sensor works fine but the signal isn't reaching the ECU (or it is but randomly), so i need to check the plug/socket connections between the engine and the chassis.

 

Apart from beating the ecu sensor with a hammer i've not been over this engine, and we only get about an hour a week to work on it (work/kids/sleep/etc), so where are the junctions? We've already got the wheel off and the ecu pulled, looking for any moisture damage (none visible) and after the junctions i'll be doing a continuity test (once i find the pin on the ecu plug that is), might just run a fresh wire from the sensor to the ecu to take that out of the equation.

 

Thanks for your help.

Just talking to myself for anybody that finds this thread from a search, it's a one piece loom. From sensors to ecu is all one piece, makes continuity testing much nicer.

 

And our problem turned out to be moisture inside the ecu, cracked it open and there was a very clear white water mark where it had got wet and dried. Gave it a bath and a brush over with some isopropyl alcohol and it's starting perfectly now. Happy days :)