I just changed my fuel filters and my fuel primer pump. I have an '83 300SD. I have been unable to get the car started after changing everything. Here is what I did. Remove secondary filter and fill new one up with fuel and screw on. Remove Primary filter and replace with new. Then I removed the primer pump and put the new one on. Pumped a bunch, primary filter was full of fuel with only one small bubble in it, kept pumping til i heard a slight hiss. tried to start car to no avail. I am assuming I got air in the system somewhere. Where should I start to remedy this? I read that I should crack the fuel lines. Where do I do that at, where they go into the injectors from the pump, or at the pump where they go out to the injectors? Did I do something wrong? The new primer pump leaks a little around the bottom. I got it as tight as I could. Maybe I need a new Compression washer for it? Any suggestions would be great.

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1983 300SD Turbo Diesel Automatic

When I prime with the pump do I need to loosen something somewhere to let the air out. I have the old style pump by the way.

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1983 300SD Turbo Diesel Automatic

Justin - it may be that all you need to do is let the starter spin for maybe two to three minutes with your foot pushing the gas(sic) pedal all the way to the floor. It will pump the fuel through the hoses and should start. I have run my 81 300SD out of fuel a few times and each time it restarted as above.

Moderator EDIT:

DANGER: Never run the starter longer than 60 seconds of continuous cranking, then give it at least 5 minutes to cool down or you risk starter failure. :EDIT:

Pump the primer pump until you hear the bypass valve.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

how will I know if I hear the bypass valve?

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1983 300SD Turbo Diesel Automatic

Your starter will probably melt into goo if you use it for two to three minutes continuously.

Crack the big nut on top of the big fuel filter that connects to the "cigar" hose. I think it's 17mm but I'm not going out to the garage to check. Pump until just clear diesel comes out with no bubbles and tighten it down.

Did you replace the washer on the primer pump with a new one along with the pump? may just need to be snugged down some.

The old style pumps are known to leak, but you did say you replaced it, buut with an old style. The new style Bosch style are nice and simple to use. nothing to unscrew, just pump.

You could have air in the lines from the IP to the Injectors. loosen the injector fuel line nuts, crank the engine over until you see clear fuel leaking with no bubbles, then tighten the nuts down on each one that runs clear.

Not a good idea to crank over the engine until it starts with an empty fuel filter if that is what was mentioned above. always fill the filter first. no since taxing the starter for a long while to start it. can over heat it.
He might have ment, after filling the filter and pumping the primer, to crank until it starts. In this case it just take a little cranking to purge any air in the Injector lines.

Sometimes what one person is thinking and typing, and some one else is reading, precieving and thinking as they read, gets interperted differently.
(A twisted mind )

I hope by this time you have her up and running.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

ok, first thing first.if fuel is leaking. you have to fix that.
if you changed the primer and it's leaking, either you crossthreaded it, or you failed to change the washer, or it's not tight enough. they don't need a lot of torque to tighten though.

once you have the leak fixed, then you need to get the air out of it.
look at the top of the filter. there are two banjo bolts, one with an arrow pointing to the center bolt, and one pointed to the engine. loosen the one pointed to the engine. then pump the primer until only fuel exits, and tighten it back up .
next get either a 17mm crowsfoot socket, or an open end wrench and loosen every line where they connect to the injectors. about 1/4 turn is plenty. then have someone crank the car for up to 30 seconds at a time. watch for bubbles and fuel to exit the nuts. as it's cranked, and the bubbles stop, tighten the lines from the back of the motor to the front. when all are tight if it has not started, let the starter cool for 10 minutes or so, then let the glow plugs warm up fully for 45 seconds, then turn them off and let them warm for another 45 seconds, then off again, and warm another 30 seconds, and then crank.
it should instantly fire!

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Thanks guys. I loosened the 17mm bolt on top of the filter and pumped away until no bubbles. Tightened it down and pumped some more. Started right up! I really appreciate the help, I was afraid I was going to damage my starter or my injection pump. Running like a champ now!

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1983 300SD Turbo Diesel Automatic

Charlie - you are correct. Although I ran out of fuel a couple of times, the fuel filter was still full. Certainly it is not good on the starter to crank it for two or three minutes, but once or twice is not going to kill it. Just not a good thing to do on a regular basis. I successfully started my 81 300SD this way maybe three times but I did pump it up after pouring in some fuel.

You may be thinking of gasser starters. The instructions for starting 617's in cold weather tell the user to keep the starter turning until the engine is firing on enough cylinders to run on its own. Below zero this can take quite a while. The starters are designed to deal with these conditions.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13