I'm hoping someone can help i have TXS 2.2. I was having an issue where the car wouldnt start when hot. I changed the crank sensor and fuel filter which didn't make a difference. Now the car won't start at all unless I hand prime it while someone sits in side and starts it. Any ideas what the problem could be. Thanks

There's a leak in the fuel lines allowing fuel to drain back to the tank. Possibly caused by incorrect filter installation.

Agree with the air leak...

Depends on the exact filter design (picture?)

Any evidence of bubbles in the fuel line?

May need to vacuum test the system from return line to filter inlet at engine to narrow it down if the filter changes hasn't caused it?

Plastic components especially) or connectors can develop tiny cracks/leaks that allow air to get in, believe me!

When I manage to get it running it runs and drive as it should but once I turned it off after a few minutes it won't start again. If I take the hose to the tank to the filter and turn it over no fuel comes out. I have put a link to the filter I used as I couldn't attach a pic

https://www.eurocarparts.com/p/bosch-fuel-filter-503545177?utm_source=google&utm_medium=cpc&utm_campaign=610675635&utm_content=70461851759&utm_term=&type=shopping&gad_source=1&gad_campaignid=610675635&gclid=CjwKCAjwg_nNBhAGEiwAiYPYA9X9c_sdV3G9-FCuXjVAzRZ4m0WRa5nIBo3re2-NwzwQ6n9lUbEtLxoCgc0QAvD_BwE

12 hours ago, Catchy said:

If I take the hose to the tank to the filter and turn it over no fuel comes out.

Correct. These do not use a low pressure pump in the fuel tank. Any minor splits in the pipework will allow the fuel to drain back to the tank when you stop the engine.

16 hours ago, TomsFocus said:

There's a leak in the fuel lines allowing fuel to drain back to the tank. Possibly caused by incorrect filter installation.

Filter is definitely fitted correctly. It was running ok. It just had the issue of not starting when hot only when engine was cold would it start. It had this problem before the Filter change

1 hour ago, TomsFocus said:

Correct. These do not use a low pressure pump in the fuel tank. Any minor splits in the pipework will allow the fuel to drain back to the tank when you stop the engine.

I thought the 2.2 had a low pressure pump in the tank

Just now, Catchy said:

I thought the 2.2 had a low pressure pump in the tank

Most of the Ford diesels around 2010 have the pump fitted, it just isn't powered. (Ford saved a few pence on the extra wiring...) Unfortunately I don't know enough about a 2012 S-Max specifically so will probably have to leave this one for another member.

If yours does need a pump and you can't hear it priming any more then that will be the reason it doesn't start.

Agree again, need to confirm the use or otherwise of an in-tank pump (2011, 2.0 does not have one AFAIK or if it does, it has never worked!)
If it won't start after a few minutes, that is likely a serious leak?
Other option is, as said to draw fuel through with vacuum pump which can then also be used to vacuum test the system until you narrow down the source of the leak:
https://www.ebay.co.uk/itm/366004354454
Only a suggestion, as this does vacuum AND pressure which makes it more useful long term.
Another suggestion is to coat each union with grease to seal up any leaks there (one at a time so you know when it is fixed - if it's a connector)
Does it have any other boxes like a fuel heater in circuit?
Even a new filter could be faulty but hopefully that is unlikely?
Ours has a clear section in the fuel line and, if present somewhere is a certain diagnostic of air in fuel (any bubbles are bad news!) - that is the strongest evidence - what can you see?

Edit: The filter seems to have fuel inlet and outlet plus return line inlet and outlet plus some sort of plug in the top and maybe a drain for water at the bottom plus a plug for heater or water detection, so lots of connections and options there?

starter