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I have a 04MY C-Max Ghia with a 2.0 TDCI (Peugeot) engine. I work at a main dealer franchise (not Ford) and therfore we service staffcars in our workshop.We did a full service and after replacing the fuel filter and using a hand primer we couldn't get it to start. After plenty of cranking we killed thestarter motor and discovered that the filter housing outletto high pressure pump pipe wasn't sealing. After correcting this fault it ran perfect for about a week and one morning my wife complained of lack of power and on idle it cut out. We were unable to restart the vehicle and so I had it recovered to a diesel specialist. To cut a long story short, we replaced the fuel rail complete with sensor (which I got from a Peugeot dealer - £100 cheaper) and now it runs fine.

The only problem I have nowis that at approx 1/4 tank it splutters and on a slope it cuts out. We believe that there may be an air leak when the fuel level gets low but without taking the tank out we can't be too sure and I've already spent over £300.Any advice would be helpful it anyone has experienced similar problems. Many thanks.
 

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Not having had this problem I can't say for certain
My first thoughts are that as it happens at lower fuel tank level and on a slope that there is a problem with the pick up pipe/ tank sender unitin the tank itself
There are supposed to be some clear plastic sections to the fuel lines. Can you see any air in the fuel?
The TIS disc then suggests going along with a small quantity of clean engine oil and putting a small amount on each fuel line joint in turn to see if the air reduces
 
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