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The return line should absolutely be free of air. Air in the return line means air is entering the fuel system somewhere. If you've bypassed the fuel heater setup and you're coming from a temporary bucket, you can rule out the hard fuel lines (although the fuel heater is still a suspect!).
The air can come from anywhere, the crush washers on the filter housing, the flare nut on the lift pump, the lift pump itself, the O-ring seals on the filter nut, etc.
Make sure you're using the correct size rubber hose (7mm) and fuel injection style clamps. Worm clamps and 5/16 hose can give you leaks that you just can't seem to track down.
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Current stable:
1995 E320 149K (Nancy)
1983 500SL 120K (SLoL)
Black Sheep:
1985 524TD 167K (TotalDumpster™)
Gone but not forgotten:
1986 300SDL (RIP)
1991 350SD
1991 560SEL
1990 560SEL
1986 500SEL Euro (Rusted to nothing at 47K!)
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