Need help.
 

1981 MB 240D. 54,xxx miles. car will not start. Replaced glow plugs with afterglow kit. Replaced primary fuel filter, going to store to replace secondary. Have not cracked injector yet to see if it is getting fuel, but the car acts as if it is not. Just cranks, no ignition whatsoever. Car ran excellent up to this point. Faster than my original 300D. No blow by. Valves adjusted 3000 miles ago. Running rotella syn 5w-40. Problem started a week ago, when I started the car in the cold. Started right up as it always does, and then after 10 seconds died. Have not been able to start since. Appreciate any help, this forum is invaluable. I will be gone for the next hour getting secondary filter.

Fill the spin-on filter with power service, fuel, etc. Make sure you prime the hand pump until it's completely full (you will hear a different sound). Once the engine catches again, give it some pedal to keep it running and get all the air out. Also, make sure the connections are all tight, so you don't have any air leaks.

Answer:
 

Try simple answers first:

#1. Assume the fuel gauge is wrong = empty tank = add several gallons, prime the system, and try again.

#2. Look for damp, cracked fuel lines sucking air.

#3. Test glow plugs.

Cold weather starting links
http://www.peachparts.com/shopforum/diesel-discussion/137674-cold-weather-starting-links.html#post1018529

Glow plugs link thread All diesel models
http://www.peachparts.com/shopforum/diesel-discussion/137732-glow-plugs-link-thread.html#post1019018

Starter health is important to your diesel!!!
http://www.peachparts.com/shopforum/diesel-discussion/107318-starter-health-important-your-diesel.html#post739798

Battery Safety
http://www.peachparts.com/shopforum/diesel-discussion/141479-battery-safety.html#post1057827

Battery selection / Charging System / jump starting / cold weather battery issues
http://www.peachparts.com/shopforum/diesel-discussion/141516-battery-selection-charging-system-jump-starting-cold-weather-battery-issues.html#post1058189

pumped the primer and fuel was spilling out below the top of the white plunger. I assume this means the system is primed, or does it mean I need a new primer?

put five gallons of diesel in also just eliminate fuel gauge.

No
 

This means the primer pump is junk, and MUST be replaced.

http://www.peachparts.com/Wikka/PrimerPump


PART NUMBER SEARCH RESULTS WITH PRICES
Vehicle 1981 Mercedes Benz 240D
Part: Primer Pump
D2010-268357 Diesel Primer Pump Bosch IN STOCK

appreciate it. Is this where the air would be entering the fuel system?

Yes
 

YES, and YES, + it is not priming the system when you pump.

okay guys, replaced primer, replaced secondary fuel filter, no go. Cracked lines at injector, no fuel. She cranks great. Battery is good. What did I lose in the IP.

after cranking, I was able to see fuel coming from the top of the IP from the cracked fuel lines. Cranked another 3 times for 20 sec. each. No fuel making it to the top of the injectors. WTF.

Fill secondary filter with fuel?
Cranking that long won't fill it.
Good luck.

Do not totally fixate on the fuel system yet. Get a meter or test light and a helper. Turn ignition switch to the glow position? Do you have voltage at the glow plugs? If it is really cold there plug the block heater in as well beforehand. Since you did not state where in the country you live is gelled up summer fuel a possibility? By spraying wd 40 into the intake with the top off the air cleaner it should run if it is fuel related somehow. But only if the glow circuit is functional.

no start
 

Whoa!

Your last post almost reads as if you've loosened the fuel line capnuts on
top of the Injection Pump barrels?
If so, the fuel will never get to the top of the injectors.
Instead, loosen the fuel line capnuts on top of each individual injector and
crank till fuel shows. [in 10 second bursts , with a 30 second rest in between
to save the starter]

rmleedom,

Did U check the tank strainer? Remove the rubber fuel line below the fuel tank where it connects to the steel fuel line and see if fuel runs out. If no fuel comes out, the strainer is plugged probably by fungus that grows in the fuel.

P E H

You may want to check the fuel pump that the primer attaches to and make sure it is still working and not clogged up. If you suspect the fuel pump go pull one from a parts car that works and try it out before shelling out the big bucks. If you get fuel and it runs you can make a choice, spend a couple hundred on a new one or keep using the used one that works. Good luck.