This is a good one. Was any work done to the car during the week leading up to when it started doing it? It is the part about how it does it once and then is fine rest of the day that is interesting.

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Jim

Nope- she ran fine for a couple of weeks after I bought her. Wasn't a function of someone working on the car. Inspected fuel lines-no obvious leaks. Only one time I couldn't start her from home and had to have her towed to shop. This was before the wiring harness was replaced.
If only MB had left the manual primer pump on this model, I could deal with it much easier.

Its an OBDi system, not OBDii. I think you can build you own blink code reader with parts from radio shack. Search ARTHUR DALTON CODE READER on this site. Diesels didn't provide as much data as gassers did in that era.

No K40 on a 95, but does have an OVP relay. Does the 95 have a shut off valve (electro-magnectic SOV) on the side of the IP? I think not; if it does, look at its oring or the SOV itself. Since the OVP was repalced I'd guess the SOV oring if it has one since it sounds like it doesnt ever "fail" to start (K40 doesn't send power to open it so the IP receives no fuel) which is a symptom of a bad K40 relay adn more rarely bad SOV.

Assuming no SOV, I'd look for a fuel line air leak or clogged tank screen that limits fuel when it gets warmed up (expansion, etc). With a working lift pump, frothy fuel is about the only thing that kills a running diesel.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

the only trouble codes that concern anything called "diesel control system" in a 606 powered W124 are of ELR

they show up as

tach sensor
temp sensor
ELR actuator
short circuit to ELR
open circuit to ELR
ELR dead

Which only are for the idle control system, the engine will run without it with no problem.

The SOV in a 606engine W124 is a vacuum type like the oldest mercedes diesels. The most simplest way to start this engine is to run it from a jug of diesel with both fuel lines dipped in it. It should fire if the engine is timed correctly, is getting air, getting fuel and has compression. Nothing else to it.

I would also suggest you to get the cat convertor inspected, I have experienced a blocked cat in this car. it can cause engine shutdown due to increased crankcase pressure, and will refuse to start for at least an hour. The pump gurus here can tell you why that happens

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Is there any way the ignition switch can malfunction and supply a shutoff vacuum to the IP?

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1995 E300 Diesel

the switch is a mechanical valve for the shutoff, it connects the vacuum line from the engine to the pump, as soon as the key is twisted to ON, the vacuum port is shut and vacuum cannot pull the diaphragm when the engine fires.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Thinking about the possibility of a clogged cat. I can see why it could stop the engine, but wouldn't it stop more sporadically, i.e. anytime during normal driving, rather than the usual 1 mile from my house?

well, my experience with the blocked kitty cat was so intense the car was undriveable completely. But it did let the engine fire and idle for periods of time, it would die if I would accelerate the engine to about 4000 rpm, it would take quite a struggle though.

Can you start the engine and rev it at a standtill? does it want to rev? the OM606 revs like a high performance gas engine beyond 2500 rpm. Check the exhaust flow at the back, the OM606 is a 4 valve head and moves A LOT of air. If you can feel a solid pressure from the exhaust your cat is probably OK.

The problem then lies in the fuelling system, Check the SOV O ring.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Engine revs smoothly at idle-had it up near 4000 rpm, with no stumbling, and solid exhaust pressure at tailpipe.

Will have to look into the SOV O-ring. and any possible hitches in the fuel delivery lines.

I did not read the thread super closely to check, but if you have not done it, please try a new lift pump. Relatively small money. This fixed a stalling-after-running-a-few-minutes problem I had. Check when the car stalls - open the fuel tank - do you get a whoosh?

Rgds,
Chris W.
'95 E300D, 368K

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Objects in closer are mirror than they appear.

Sorry for the late reply- was out of town. Don't remember experiencing the whoosh sound, but my Mechanic is going over everything again this week with all your suggestions and will post in a week-week and a half when I'm back. Thanks for all the input.