I've been having some starting problems for months on the '83 300D and I had isolated it to the fuel system losing it's prime. I see a rush of air bubbles when I rev the engine from the clear hard line on the back of the injection pump going into the secondary filter. I do not have any air bubbles in the primary clear filter.

I have the new style primer pump and I replaced all the copper washers. I also replaced the washers on the banjo bolt on the back side of the IP on the line where I see the bubbles and Voila!! Started perfect....first time in months... It remained perfect for about a week and then...just like that ...it was back t it's old ways. I re-replaced all the crush washers and inspected everything. I don't think I have a leak in the lift pump because I would see air bubbles in the primary filter...right?

The only thing I can think of is I replaced the aluminum washers on the banjo bolts with copper....should that make a difference?

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1980 300SD 237k
1983 300D 195k (sold)
2003 Chevy Silverado 190k